HD465 7 Shop Manual SN 7001 Up PDF

SEBM027612
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 mount the SAA6D170E-3 engine.

For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2006
All Rights Reserved 00-1
Printed in Japan 02-06(02) (12)
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
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20-1156 (10) Q 20-1270 (12) 30-7 (10) 30-58 (3) 30-110 (10)
20-1157 (10) Q 20-1271 (12) 30-8 (10) 30-59 (3) 30-111 (10)
20-1159 (10) Q 20-1272 (12) 30-9 (10) 30-60 (10) 30-112 (3)
20-1160 (10) Q 20-1273 (12) 30-10 (10) 30-61 (3) 30-113 (10)
20-1161 (10) Q 20-1274 (12) 30-11 (3) 30-62 (3) 30-113-1 (10)
20-1162 (10) Q 20-1275 (12) 30-12 (10) 30-63 (3) 30-113-2 (8)
20-1163 (10) Q 20-1276 (12) 30-13 (10) 30-64 (3) 30-113-3 (10)
20-1164 (10) Q 20-1277 (12) 30-14 (3) 30-65 (3) 30-114 (3)
20-1165 (10) Q 20-1278 (12) 30-15 (10) 30-66 (3) 30-115 (10)
20-1166 (10) Q 20-1279 (12) 30-16 (3) 30-67 (3) 30-116 (3)
20-1167 (10) Q 20-1280 (12) 30-17 (10) 30-68 (3) 30-117 (10)
20-1168 (10) Q 20-1281 (12) 30-18 (3) 30-69 (3) 30-117-1 (10)
20-1169 (10) Q 20-1282 (12) 30-19 (3) 30-70 (3) 30-117-2 (8)
20-1170 (10) Q 20-1283 (12) 30-20 (3) 30-71 (3) 30-117-3 (10)
20-1171 (10) Q 20-1284 (12) 30-21 (10) 30-72 (3) 30-118 (10)
20-1172 (10) Q 20-1285 (12) 30-22 (10) 30-73 (3) 30-119 (10)
20-1173 (10) Q 20-1286 (12) 30-23 (10) 30-74 (3) 30-120 (10)
HD465-7, HD605-7 00-2-5

(12)
30-121 (3)
30-122 (3)
30-123 (3)
30-124 (3)
30-125 (3)
30-126 (3)
30-127 (3)
30-128 (3)
30-129 (3)
30-130 (10)
30-131 (3)
30-132 (3)
30-133 (3)
30-134 (3)
30-135 (4)
30-136 (3)
30-137 (3)
30-138 (3)
30-139 (3)
30-140 (3)
30-141 (10)
30-142 (3)
30-143 (3)
30-144 (7)
30-145 (4)
30-146 (4)
30-147 (10)
30-148 (4)
30-149 (10)
30-150 (4)
30-151 (4)
30-152 (10)
q 90-1 (12)
90-2
q 90-3 (12)
q 90-5 (12)
90-7
90-9
90-11
90-13
90-15
90-17
90-19 (7)
90-21 (7)
90-23 (10)
90-25 (10)
Q 90-26-1 (12)
Q 90-26-3 (12)
q 90-27 (12)
Q 90-29 (12)
00-2-6 HD465-7, HD605-7

(12)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any 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
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) 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
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
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.
k
Special safety precautions
Safety 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. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
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
k 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
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 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 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
k Slinging with one rope may cause turning

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(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.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
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
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
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
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
! When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
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, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 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 metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• 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, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

! In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
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.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 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 Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 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 20.6
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 — – 12UN 30.2
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) (mm2)
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- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL
6
Color — — — Red & Blue Yellow & White Green & Blue
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 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
(C)
(A) 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
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 04-05
01 GENERAL
Specification drawings....................................... 01- 2

Specifications .................................................... 01- 3
Weight table ...................................................... 01- 9
Fuel, coolant and lubricants .............................. 01-10
HD465-7, HD605-7 01-1

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

GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HD465-7
Serial No. 7001 and up
Empty kg 42,800
Max. load kg 55,000
Gross kg 97,875
Weight
(front) kg 20,120 (47%)

Empty
distribution
Weight
(rear) kg 22,680 (53%)
(front) kg 31,320 (32%)

Gross
(rear) kg 66,555 (68%)
Struck m3 25
Dump body capacity
Heaped (2 :1) m3 34.2
Performance
Max. travel speed km/h 70
Gradeability (sin ) % 37
Min. turning radius m 8.5
Dumping angle ° 48
Overall length mm 9,355
Overall width mm 4,595
Overall height mm 4,400

Dimensions
Wheel base mm 4,300
Front wheel mm 3,515

Tread
Rear wheel mm 3,080
Ground clearance mm 645
Model KOMATSU SAA6D170E-3
Type 4-cycle, water-cooled, in-line 6-cylinder,

direct injection, with turbocharger and after-cooler
No. of cylinders – Bore x stroke mm 6 – 170 x 170
Piston displacement {cc} 23.15 {23,150}
Engine
Rated output kW/rpm{HP/rpm} 533/2,000 {715/2,000}

Max. torque Nm/rpm{kgm/rpm} 3,256/1,400 {332/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 207 {154}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 50A
Battery 12V, 200Ah x 2 units
HD465-7, HD605-7 01-3

(10)
Structure 3-element, 1-stage, 2-phase

Torque converter
Lock- up clutch Hydraulically actuated, wet-type, multiple-disk clutch
TORQFLOW planetary gear

Type Fully automatic, electrically-hydraulically
Transmission actuated, force-feed type pump
Power train
No. of speeds F7, R1
Type Spiral bevel gear, splash lubrication
Reduction gear Reduction ratio 3.538
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.737
Steering
system
Type Fully hydraulic steering system
Front axle Independent suspension (Mac Pherson type)

Suspension
Axle type
Rear axle Full floating
Front axle Hydropneumatic

Suspension method (Automatic damping force selection type)
Rear axle Hydropneumatic
Front tire 24.00 – 35 – 36PR x 2

Size and No.
Tires
Rear tire 24.00 – 35 – 36PR x 4
Tire pressure Front and rear tire kPa {kg/cm2} 470 {4.75}
Front wheel Single dry disc type, Hydraulically controlled

Service brake
Rear axle Oil cooled multiple disc brake, Hydraulically controlled
Breke system
Multiple disc wet type disc brake,

Parking brake Hydraulically released spring type
Retarder Oil cooled multiple disc type, Hydraulically controlled
01-4 HD465-7, HD605-7

(10)
For both steering and work equipment
Type Gear pump
Delivery /min 348

(at engine rated speed 2,000 rpm)
Hydraulic pump
For charging torque converter
Type Gear pump
Delivery /min 228

Hydraulic system
For brake cooling
Type Gear pump
Delivery /min 456

Hoist cylinder
Type 2-stage piston type

(only 2nd stage: double-acting)
Cylinder
No. – bore (1st – 2nd) x stroke 2 – (170 mm – 150 mm) x 1,774 mm
Steering cylinder
Type Piston type, double acting
No. – bore x stroke 2 – 85 mm x 410 mm
HD465-7, HD605-7 01-5

Empty kg 45,900
Max. load kg 63,000
Gross kg 108,975
Weight
(front) kg 21,575 (47%)

Empty
distribution
Weight
(rear) kg 24,325 (53%)
(front) kg 34,870 (32%)

Gross
(rear) kg 74,105 (68%)
Struck m3 29
Dump body capacity
Heaped (2 :1) m3 40
Performance
Max. travel speed km/h 70
Gradeability (sin ) % 37
Min. turning radius m 8.5
Dumping angle ° 48
Overall length mm 9,355
Overall width mm 4,595
Overall height mm 4,400

Dimensions
Wheel base mm 4,300
Front wheel mm 3,515

Tread
Rear wheel mm 3,080
Ground clearance mm 645
Model KOMATSU SAA6D170E-3
Type 4-cycle, water-cooled, in-line 6-cylinder,

direct injection, with turbocharger and after-cooler
No. of cylinders – Bore x stroke mm 6 – 170 x 170
Piston displacement {cc} 23.15 {23,150}
Engine
Rated output kW/rpm{HP/rpm} 533/2,000 {715/2,000}

Max. torque Nm/rpm{kgm/rpm} 3,256/1,400 {332/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 207 {154}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 50A
Battery 12V, 200Ah x 2 units
01-6 HD465-7, HD605-7

(10)
Structure 3-element, 1-stage, 2-phase

Torque converter
Lock- up clutch Hydraulically actuated, wet-type, multiple-disk clutch
TORQFLOW planetary gear

Type Fully automatic, electrically-hydraulically
Transmission actuated, force-feed type pump
Power train
No. of speeds F7, R1
Type Spiral bevel gear, splash lubrication
Reduction gear Reduction ratio 3.538
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.737
Steering
system
Type Fully hydraulic steering system
Front axle Independent suspension (Mac Pherson type)

Suspension
Axle type
Rear axle Full floating
Front axle Hydropneumatic

Suspension method (Automatic damping force selection type)
Rear axle Hydropneumatic
Front tire 24.00 R35 aa x 2

Size and No.
Tires
Rear tire 24.00 R35 aa x 4
Tire pressure Front and rear tire kPa {kg/cm2} 686 {7.0}
Front wheel Single dry disc type, Hydraulically controlled

Service brake
Rear axle Oil cooled multiple disc brake, Hydraulically controlled
Breke system
Multiple disc wet type disc brake,

Parking brake Hydraulically released spring type
Retarder Oil cooled multiple disc type, Hydraulically controlled
HD465-7, HD605-7 01-7

(10)
For both steering and work equipment
Type Gear pump
Delivery /min 348

Hydraulic pump
For charging torque converter
Type Gear pump
Delivery /min 228

Hydraulic system
For brake cooling
Type Gear pump
Delivery /min 456

Hoist cylinder
Type 2-stage piston type

(only 2nd stage: double-acting)
Cylinder
No. – bore (1st – 2nd) x stroke 2 – (170 mm – 150 mm) x 1,774 mm
Steering cylinder
Type Piston type, double acting
No. – bore x stroke 2 – 85 mm x 410 mm
01-8 HD465-7, HD605-7

GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model HD465-7 HD605-7
Serial Number 7001 and up 7001 and up
Engine assembly 2,740 2,740

Output shaft assembly 123 123
Radiator assembly 304 304
Fuel tank 276 276
Torque converter assembly 403 403
Transmission assembly 1,184 1,184
Drive shaft assembly (front) 28 28
Drive shaft assembly (rear) 62 62
Rear axle assembly 6,355 6,355
• Differential 822 822
• Final drive (one-side) 1,502 1,502
• Rear brake (one-side) 646 646
Front axle (one-side) 330 330
Front brake (one-side) 142 142
Front suspension cylinder 460 460
Rear suspension cylinder 172 172
Frame 4,698 4,698
Cab (Platform) 920 920
Operator's seat 63 63
Steering cylinder 44 44
Hoist cylinder 206 206
Demand valve 26 26
Steering valve 20 20
Hoist valve 34 34
Hydraulic pump (SAR(3)–100+100) 28 28
Hydraulic pump (SAR(3)–80+80) 33 33
Hydraulic pump (SAR(3)100+(1)25) 23 23
Dump body 10,730 13,418
HD465-7, HD605-7 01-9

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

(10)
GENERAL FUEL, COOLANT AND LUBRICANTS
Engine Oil Transmission Steering, Front Rear Differential

Pan Case Hoist Oil Tank Suspension Suspension Case
Specified 17 each for 11.3 each for

67 285 180 95
capacity ( ) right and left right and left
Refill capacity
57 190 122 — — 95
( )
Final drive Cooling

Fuel tank
case system
Specified oil 32 each for

780 154
level ( ) right and left
Refill capacity 21 each for

— —
( ) right and left
Fuel and oil

Select fuel and oil according to the above table.
Coolant
Since Komatsu genuine Supercoolant (AF-ACL) is
added to the cooling water, the latter does not need
to be replaced while the atmospheric temperature is
above – 10°C. If the atmospheric temperature drops
below – 10°C, adjust the concentration of AF-ACL
according to the operation and meintenance manual.
a The specified capacity means the total amount of

oil including oil for components and oil in piping.
The refill capacity means the amount of oil
needed to refill the system during normal inspec-
tion and maintenance.
a When starting the engine in an atmospheric tem-

perature of lower than 0°C, be sure to use
e n g i n e o i l o f S A E 1 0 W, S A E 1 0 W - 3 0 o r
SAE15W-40, even through the atmospheric tem-
perature goes up to 10°C or above during the
day.
HD465-7, HD605-7 01-11

(10)
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
ECMV ......................................................... 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 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 temperature 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

(10)
RADIATOR, TORQUE CONVERTER
OIL COOLER, AFTER COOLER, WORK
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EQUIPMENT OIL COOLER, FUEL COOLER
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER

COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER
1. Pick-up for radiator coolant level sensor Specifications

2. Upper tank Radiator
3. Lower tank Core type: CF4-5
4. Core Total radiation surface: 130.6 m2
5. Work equipment oil cooler
6. After cooler Work equipment oil cooler
7. Fuel cooler Core type: CF40-1
Radiation surface: 2.90 m2
A : Coolant inlet port
B : Coolant outlet port Fuel cooler
Core type: FC1-3
Heat radiation area: 6.75 m2
HD465-7, HD605-7 10-3

(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE OIL COOLER
BRAKE OIL COOLER
1. Cooler element Oil cooler specifications

Element type : Multiple plate
A : Oil inlet Radiation surface: 8.13 m2
B : Oil outlet Pressure resistance (oil side): 2.9 MPa {30 kg/cm2}
C : Coolant inlet
D : Coolant outlet
10-4 HD465-7, HD605-7

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion Function

2. Outer body The output shaft is installed to the engine flywheel,
3. Flange and absorbs the twisting vibration caused by
4. Shaft changes in the engine torque.
5. Coupling
6. Inner body
7. Cover
10-6 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
Unit: mm
No. Check item Criteria Remedy

Tolerance Standard
Standard size Clearance limit
Clearance between flywheel Shaft Hole clearance
1
and bearing
0 –0.010 –0.045 –
100 0.02
–0.015 –0.045 0.005
Clearance between shaft and –0.010 0 –0.005 – Replace

2 55 0.10
bearing –0.040 –0.015 0.040
Clearance between bearing +0.006 –0.008 –0.039 –

3 150 0.06
and cover –0.024 –0.033 0.016
Clearance between bearing +0.025 +0.005 –0.050 –

4 85 0.013
and shaft +0.003 –0.025 0.002
Standard size Repair limit

Wear of oil seal contact sur- Repair or
5 0
face of coupling 110 replace
–0.1
Standard backlash Backlash limit

6 Backlash at spline
0.080 – 0.231 0.4
Standard backlash
Original dimension: Lo
(Dimension at smallest width: L) Replace
Defomation of rubber cushion
7 90 81
75 67
External No cracks
HD465-7, HD605-7 10-7

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1. PTO Gear (Number of teeth : 91) Specification

Type : 3-element, 1-stage, 2-phase
A : Main oil pressure detection port With modulation
B : Torque converter oil inlet With lock-up clutch
C : Torque converter oil inlet pressure detection port Lock-up clutch : Wet type double plate clutch
D : Torque converter oil outlet Hydraulic control
E : To transmission control valve (with modulation mechanism)
F : To lock-up clutch Stall torque ratio: 2.32
G: Torque converter oil outlet pressure detection port
H : To transmission lubrication
10-10 HD465-7, HD605-7

(10)
1. Coupling 10. Stator shaft

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

10-12 HD465-7, HD605-7

Unit: mm

Standard size Tolerance Repair limit
Coupling oil seal sliding por-
1 0
tion outside diameter φ 110 φ 109.8
–0.087
Correction
Input shaft seal ring sliding +0.025 by chrome
2 φ 35 φ 35.1
portion inside diameter 0 plating or
replace-
Pump housing seal ring slid- +0.040 ment
3 φ 135 φ 135.5
ing portion inside diameter 0
Input shaft seal ring sliding +0.030

4 φ 75 φ 75.1
portion inside diameter 0
0
Stator shaft seal Width 3.95 3.55
5 –0.1
ring wear
Thickness 5.1 ±0.1 4.59
Outer race one-way clutch

6 transmission face inside φ 127.844 ±0.013 φ 127.874
diameter
Inner race one-way clutch

7 transmission face outside φ 108.883 ±0.013 φ 108.853
diameter
Bushing sliding portion inside +0.040

8 φ 108.96 φ 109.04
diameter +0.018 Replace
Bushing sliding portion thick- 0
9 5 4.5
ness –0.1
10 Clutch disc thickness 5.4 ±0.1 4.8
Tolerance Standard
Clearance between clutch Shaft Hole clearance
11
housing and piston (outside)
–0.5 +0.097
φ 420 0.5 – 0.797 0.88
–0.7 0
Clearance between clutch –0.110 +0.081

12 φ 295 0.11 – 0.272 0.30
housing and piston (inside) –0.191 0
HD465-7, HD605-7 10-13

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

(9)
OIL FLOW
• After the oil passed through the main relief valve,

the torque converter relief valve adjusts the oil
pressure below the set pressure. Then, the oil
enters the input port A, passes through the oil
route of the stator shaft (1) and flows to the
pump (2) from between the pump (2) and the
stator (3). The oil enters the turbine (4) after
getting centrifugal force from the pump (2) and
transmits its energy to the turbine (4).
The oil from the turbine is forced to flow to the
stator (3) and enters the pump again. But part
of the oil passes through between the turbine (4)
and the stator (3), flows to the oil cooler for cool-
ing from the outlet port B and is used for lubricat-
ing the transmission.
HD465-7, HD605-7 10-15

(9)
TORQUE CONVERTER VALVE
Unit: mm

Tolerance Standard
Clearance between torque Shaft Hole clearance
1
converter spool and body
–0.035 +0.016 0.035 –
32 0.081
–0.045 0 0.061
Clearance between main relief –0.035 +0.016 0.035 –

2 32 0.081
spoon and body –0.045 0 0.061

Replace
Free length Installed length Installed load Free length Installed load
3 Main relief valve spring
1213.2 N 1153.8 N
118 94.5 114.5
{123.8 kg} {117.6 kg}
Torque converter relief valve 331.2 N 315.0 N

4 137 93.5 132.9
spring {33.8 kg} {32.1 kg}
Poppet spring (touque con- 32.0 N 30.8 N

5 26 17 25.2
verter relief, main relief) {3.3 kg} {3.1 kg}
10-16 HD465-7, HD605-7

(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-18 HD465-7, HD605-7

1. Input shaft A : Speed sensor (for input shaft)

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

10-20 HD465-7, HD605-7

1. Input shaft
2. No. 1 sun gear (Number of teeth : 34)
3. No. 1 clutch hub
4. No. 1 clutch (High)
5. No. 1 planetary pinion (Number of teeth : 32)
6. No. 1 planetary carrier
7. No. 2 clutch hub
8. No. 2 clutch (Low)
9. No. 1 ring gear (Number of teeth : 98)
10. No. 2 clutch housing
11. No. 3 clutch housing
12. No. 3 clutch drum
13. No. 3 clutch (4th)
14. No. 3 clutch hub
16. No. 4 clutch (3rd)
19. No. 5 clutch (R)
23. No. 6 clutch (2nd)
27. No. 6, 7 planetary carrier
28. No. 7 clutch (1st)
30. Output shaft
32. No. 7 clutch piston
34. Intermediate shaft (No. 7 sun gear : Number of
teeth 28)
37. No. 4, 5 planetary carrier
HD465-7, HD605-7 10-21

10-22 HD465-7, HD605-7

Unit: mm

Installed
Free length Installed load Free length Installed load
1 No. 1 clutch spring length
74.5 N 63.7 N
42.0 32.0 39.5
{7.6 kg} {6.5 kg}
49.1 N 42.2 N
2 No. 4 clutch spring 52.0 49.1 48.9
{5.0 kg} {4.3 kg}
141.2 N 119.6 N
3 No. 5 clutch spring 91.0 75.0 85.5
{14.4 kg} {12.2 kg}
113.8 N 97.1 N
4 No. 6 clutch spring 68.0 57.85 63.9
{11.6 kg} {9.9 kg}
179.5 N 153.0 N
5 No. 7 clutch spring 68.0 52.0 63.9
{18.3 kg} {15.6 kg}

Total thickness of 3 discs and
6
2 plates for No. 1 clutch 27.8 ±0.22 25.8

7 45.0 ±0.30 42
4 plates for No. 2 clutch

8 35.0 ±0.26 32.3

9 36.6 ±0.26 33.9

10 47 ±0.30 43.7
Replace
11 44.8 ±0.28 42.1

12 39.0 ±0.26 36.3
No.
5.4 ±0.10 4.8
Thickness of 1 1,4,5,6,7
13
disc
No. 2,3 5.0 ±0.10 4.4
No. 1,6,7 5.8 ±0.10 5.6

Thickness of 1
14
plate No.
5.0 ±0.10 4.8
2,3,4,5
–0.01
Wear of transmis- Width 2.56 2.30
–0.03
15 sion input shaft
seal ring (small) Thickness 1.7 ±0.10 1.55
–0.01
Wear of transmis- Width 3.0 2.70
–0.03
16 sion input shaft
seal ring (large) Thickness 3.1 ±0.10 2.95
Wear of No. 1 car- Width –0.01

4.0 3.6
rier, No. 3 clutch –0.03
17
hub and No. 4 sun
gear seal rings Thickness 4.6 ±0.12 4.45
HD465-7, HD605-7 10-23

Unit: mm

Wear of No. 2 and Width –0.01

4.0 3.6
18 3 clutch collar –0.03
seal rings
Thickness 5.1 ±0.12 4.85
–0.01
Wear of No. 4 and Width 4.0 3.6
–0.04
19 5 carrier seal
rings Thickness 6.3 ±0.15 6.15
–0.01
–0.04
20 7 carrier seal
0
–0.1
21 7 carrier seal
–0.01
–0.04
22 7 carrier seal
Backlash between No. 1 sun

23 0.13 – 0.36
gear and planetary gear
Backlash between No. 1 plan-

24 0.16 – 0.41
etary gear and ring gear
Replace
25 0.14 – 0.36

26 0.15 – 0.39

27 0.14 – 0.36

28 0.13 – 0.34
etary gear and planetary gear

29 0.15 – 0.39

30 0.16 – 0.41

31 0.16 – 0.41

32 0.13 – 0.36

33 0.17 – 0.44
34 Disc inner teeth deformation Repair limit : 0.3

Thrust washer thickness
35
(No. 1, 4 and 5 planetary gears) 2 ±0.1 1.6
Thrust washer thickness

36 3 ±0.1 2.4
(No. 6 and 7 planetary gears)
10-24 HD465-7, HD605-7

Unit: mm

Location Standard clearance Clearance limit
No. 1 gear train 0.30 – 0.80 1.5
No. 4 gear train 0.30 – 0.80 1.5

Replace the
thrust
37 Planetary gear side clearance
No. 5 gear train 0.30 – 0.80 1.5 washer or
the carrier
No. 6 gear train 0.30 – 0.80 1.5
No. 7 gear train 0.30 – 0.80 1.5
Standard size Wear

Stepped-type wear of seal
38
ring counter face — 0.05 max.
Replace
Output shaft oil seal contact
39
surface 120 119.8
Standard Tolerance Standard Clearance

Clutch No.
size Shaft Hole clearance limit
No. 1 –0.5 +0.097 0.5 –

430 0.88
Outside –0.7 0 0.797
When any
–0.135 +0.097 0.135 – damage like
Inside 405 0.36
–0.232 0 0.329 seized
streak is
No. 2,3 –0.5 +0.081 0.5 – found on
275 0.86
Outside –0.7 0 0.781 any surface,
if corrected
–0.110 +0.081 0.110 –
Middle 255 0.30 and
Clearance between cylinder –0.191 0 0.272
40 the allow-
and piston
–0.5 +0.063 0.5 – able clear-
Inside 175 0.84 ance is
–0.7 0 0.763
maintained,
No. 4,5,6,7 –0.5 +0.089 0.5 – it can be
430 0.87 used.
Outside –0.7 0 0.789
Replace
No. 4 –0.125 +0.089 0.125 – it if damaged
395 0.33
Inside –0.214 0 0.303 remarkably
No. 5,7 –0.125 +0.089 0.125 –
380 0.33
Inside –0.214 0 0.303
No. 6 –0.125 +0.089 0.125 –

375 0.33
Inside –0.214 0 0.303
HD465-7, HD605-7 10-25

Outline
• The transmission consists of an F7 R1 planetary Group Clutch pack Planetary gear
gear type transmission with a control valve.
• The transmission and torque converter are con- Front No. 1 clutch (High)
nected at the transmission input shaft. group No. 2 clutch (Low) No. 1 planetary gear
• Gear shifting is carried out automatically by the
automatic transmission according to changes in No. 3 clutch (4th)
engine speed.
No. 4 clutch (3rd) No. 4 planetary gear
Gear Shifting Function Rear
No. 5 clutch (R) No. 5 planetary gear
• The inside of the transmission consists of 7 group
clutch packs and 5 sets of planetary gears. No. 6 clutch (2nd) No. 6 planetary gear
These are divided into the front group and rear No. 7 clutch (1st) No. 7 planetary gear
group.
• One clutch pack in the front group and one clutch

pack in the rear group are actuated simulta- Speed Reduction
Clutches engaged
neously by oil pressure sent from the transmis- range ration
sion valve to give the speed range and reduction
F1 No. 2 – No. 7 (Low – 1st) 4.714
ratio. F2 No. 2 – No. 6 (Low – 2nd) 3.333
F3 No. 1 – No. 6 (High – 2nd) 2.475
F4 No. 2 – No. 4 (Low – 3rd) 1.825
F5 No. 1 – No. 4 (High – 3rd) 1.355
F6 No. 2 – No. 3 (Low – 4th) 1.000
F7 No. 1 – No. 3 (High – 4th) 0.742
R No. 2 – No. 5 (Low – R) 3.969
10-26 HD465-7, HD605-7

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

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

(9)
ECMV FOR LOCKUP CLUTCH

Outline Operation
• This valve is used for setting oil pressure of the When the torque converter is operating without
lockup clutch to the set pressure, and for switch- lockup.
ing lockup clutch.
Since the modulation actuates as shown below,
the valve enables to engage the lockup clutch
smoothly and to reduce shocks at the time of
gearshift. Also, the valve prevents the power
train from causing peak torque. This improves
operator comfort and makes the power train
more durable.
WHEN SWITCHING LOCKUP CLUTCH

(Lockup clutch OFF to ON)
WHEN SHIFTING GEAR (At direct driving)
• When the torque converter is operating without

lockup, no current is flowing to the proportional
solenoid (1).
The pressure control valve (3) drains oil from the
clutch port A through the drain port T, and the
lockup clutch is [RELEASED]. Since oil pressure
force does not work to the pressure detection
valve (4), the fill switch (5) is turned "OFF".
HD465-7, HD605-7 10-29

(10)
WHEN THE TORQUE CONVERTER IS OPERATING

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

(9)
ECMV FOR SPEED RANGE CLUTCH

Outline of ECMV ECMV and proportional solenoid
• The ECMV consists of a pressure regulator valve • One proportional solenoid is installed for one
and a fill switch. ECMV.
• Pressure control valve After receiving the command current from the
Converts a current sent from the transmission controller, it produces thrust shown in the graph
controller to the proportional solenoid valve, to below.
an oil pressure. By making the proportional solenoid-produced
• Fill switch thrust act on the pressure control valve spool, it
Detects that the clutch is filled with oil. It has the produces an oil pressure shown in the graph
functions below. below. By controlling the amount of command
1. When the clutch is filled with oil, a signal (the current, the thrust is changed to operate the
fill signal) is sent to the controller to notify pressure control valve, controlling the oil flow
that filling is finished. and oil pressure.
2. While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the Current-Propulsion force characteristics of pro-
controller to notify that oil pressure is being potional solenoid
applied.
Propulsion force-Hydraulic pressure characteris-

tics of proportional solenoid
ECMV and fill switch

• One fill switch is installed for one ECMV.
If the clutch finishes filling, the fill switch is turned
A range: Before shifting gear (when drained)
"ON" by the pressure of the clutch. By this sig-
B range: Filling
nal, the oil pressure starts build-up.
C range: Pressure regulation
D range: Filling (tiggering)
E point : Start of filling
F point : Finish of filling
a The logic is such that the controller does not rec-
ognize finish of filling even if the fill switch is
turned "ON" during the triggering operation (D
range).
HD465-7, HD605-7 10-31

(9)
ECMV operation
• The ECMV is controlled with the command cur- Before shifting gear (when drained)
rent sent from the controller to the proportional (A range in chart)
solenoid and the output signal of the fill switch.
The relationship between the proportional com-
mand current for the ECMV, clutch input pres-
sure and output signal of the fill switch is shown
in the graph below.
• When no current is supplied to the proportional

solenoid (1), the pressure control valve (3) is
draining oil from the clutch port A through the
drain port T.
Since no oil pressure works to the pressure
detection valve (4), the fill switch (5) is "OFF".
B range: Filling
D range: Filling (triggering)
range).
10-32 HD465-7, HD605-7

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

(9)
(FOR LOW, 4TH, 3RD AND 2ND CLUTCHES WITH FLOW DETECTION VALVE)
1. Fill switch connector A : To clutch

2. Proportional solenoid connector P : From pump
3. Pressure detection valve T : Drain
4. Fill switch DR: Drain
5. Proportional solenoid P1 : Clutch pressure pick-up port
6. Pressure control valve P2 : Pilot pressure pick-up port
7. Nameplate (*1)
*1: Applicable clutch Character on nameplate
Low, 4th, 3rd, 2nd D*******
10-34 HD465-7, HD605-7

(9)
ECMV FOR SPEED RANGE CLUTCH

Outline of ECMV ECMV and proportional solenoid
• The ECMV consists of a pressure regulator valve • One proportional solenoid is installed for one
and a fill switch. ECMV.
• Pressure control valve After receiving the command current from the
Converts a current sent from the transmission controller, it produces thrust shown in the graph
controller to the proportional solenoid valve, to below.
an oil pressure. By making the proportional solenoid-produced
• Fill switch thrust act on the pressure control valve spool, it
Detects that the clutch is filled with oil. It has the produces an oil pressure shown in the graph
functions below. below. By controlling the amount of command
1. When the clutch is filled with oil, a signal (the current, the thrust is changed to operate the
fill signal) is sent to the controller to notify pressure control valve, controlling the oil flow
that filling is finished. and oil pressure.
2. While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the Current-Propulsion force characteristics of pro-
controller to notify that oil pressure is being potional solenoid
applied.
Propulsion force-Hydraulic pressure characteris-

tics of proportional solenoid
ECMV and fill switch

• One fill switch is installed for one ECMV.
If the clutch finishes filling, the fill switch is turned
"ON" by the pressure of the clutch. By this sig-
B range: Filling
nal, the oil pressure starts build-up.
D range: Filling (tiggering)
range).
HD465-7, HD605-7 10-35

(9)
ECMV operation
• The ECMV is controlled with the command cur- Before shifting gear (when drained)
rent sent from the controller to the proportional (A range in chart)
solenoid and the output signal of the fill switch.
The relationship between the proportional com-
mand current for the ECMV, clutch input pres-
sure and output signal of the fill switch is shown
in the graph below.
• When no current is supplied to the proportional

solenoid (1), the pressure control valve (3) is
draining oil from the clutch port A through the
drain port T.
Since no oil pressure works to the flow detection
valve (4), the fill switch (5) is "OFF".
B range: Filling
D range: Filling (triggering)
range).
10-36 HD465-7, HD605-7

(9)
Filling (B range in chart) Pressure regulation (C range in chart)
• When a current is supplied to the proportional

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

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT
1. Wheel hub
Unit: mm

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

(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
REAR
1. Differential Specifications
2. Axle housing Reduction ratio
3. Brake Differential: 3.538
4. Final drive Final drive : 4.737
Oil
Differential: EO30-CD (95 liters)
Final drive : EO30-CD (32 liters each side)
Tire size : 24.00-35 (HD465-7)
24.00R35 (HD605-7)
Rim size: 17.00-35
HD465-7, HD605-7 10-41

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
1. Coupling Specifications
2. Cross shaft Type: Spiral bevel gear, splash-type lubrication
3. Bevel gear (No. of teeth: 46) Reduction ratio: 3.538
4. Side gear (No. of teeth: 24) Differential: Straight bevel gear, splash-type
5. Pinion gear (No. of teeth: 17) lubrication
6. Bevel pinion (No. of teeth: 13) Oil: EO30-CD (95 liters)
10-42 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm

Wear of oil seal contact sur- Repair or
7 0
face of coupling 150 — replace
–0.100
Thickness of side gear thrust 0

8 6 5.5 Replace
washer –0.050
Backlash between bevel gear

9 0.41 – 0.56 Adjust
and pinion
HD465-7, HD605-7 10-43

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Sun gear (No. of teeth: 19) Specification

2. Planet gear (No. of teeth: 31) Type: Planetary gear, splash-type lubrication
3. Planet gear shaft Reduction ratio: 4.737
4. Ring gear (No. of teeth: 87) Oil: EO30-CD (32 liters each side)
5. Inner hub
6. Wheel hub
7. Drive shaft
10-44 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Standard backlash Repair limit
Backlash between planet gear
8
and sun gear 0.22 – 0.67 0.8
Replace
Backlash between planet gear

9 0.28 – 0.77 1.0
and ring gear
Repair or
10 Curvature of drive shaft Repair limit: 1.5 TIR
replace

11 Thickness of spacer Replace
51.5 ±0.1 50
HD465-7, HD605-7 10-45

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

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 hydropneumatic cylinders, the suspension cylin-
the chassis, and absorbs the shock from uneven der is charged (sealed) with oil and nitrogen gas.
road surfaces to provide a comfortable ride for This acts as a shock absorber (spring and
the operator. At the same time, it maintains the damper) by contracting and expanding the nitro-
stability of the machine by ensuring that all four gen gas and oil to absorb the load from the road
wheels are always in contact with the ground surface.
surface. In this way, it allows the machine to • In addition to these functions, the front suspen-
demonstrate its full performance in items such as sion employs an automatic suspension system.
acceleration, braking, and turning, even when In this system, the force of the suspension is
traveling at high speed. automatically changed by selecting the dumping
• Hydropneumatic cylinders are used for the sus- force to match the travel conditions and load
pension cylinders to reduce the shock. With conditions. This further increases the stability
and riding comfort of the machine.
10-48 HD465-7, HD605-7

(10)
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 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

(10)
Unit: mm

Tolerance Standard
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 of 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

(10)
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 gets weak, 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

(10)
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. Valve (for bleeding air and mounting pressure sensor)
5. Ball
10-54 HD465-7, HD605-7

(10)
Unit: mm

Tolerance Standard
Clearance between piston rod Shaft Hole clearance
6
and bushing
–0.043 +0.246 0.043 –
180 0.4
–0.106 0 0.352
Replace
Clearance between piston rod –0.043 +0.246 0.043 –
7 180 0.4
and bushing –0.106 0 0.352
Clearance between cylinder –0.050 +0.115 0.05 –

8 220 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. Valve (for bleeding 7. Nitrogen gas chamber
In this way, the amount of oil returning to cham- and mounting pres- 8. Cylinder rod
ber (6) is restricted to provide a shock absorbing sure sensor) 9. Cylinder
effect. 2. Cavity 10. Feed valve
3. Check ball
4. Orifice a : When extending
5. Orifice b : When retracting
6. Oil chamber
HD465-7, HD605-7 10-55

(10)
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 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
outer bushing 0.180
HD465-7, HD605-7 10-57

(10)
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
outer bushing 0.250
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
outer bushing 0.250
Replace
Clearance between arm –0.030 +0.076 0.060 –
11 55 0.3

12 100 0.5
outer bushing 0.180
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
outer bushing 0.250
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

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

(12)
1. Front brake OFF 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

(10)
HD465-7 Serial No.: 7266 and up

10-63-1 HD465-7, HD605-7

(12)
1. Front brake OFF 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)
12. Reducing valve
HD465-7, HD605-7 10-63-2

(12)
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
1. Rod Function
2. Spool • This valve operates the brake depending on the
3. Cylinder parking brake release pressure controlled by the
emergency brake pedal.
A. To parking brake valve
P. From accumulator
T. To transmission oil pan
HD465-7, HD605-7 10-67

(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RELAY VALVE
RELAY VALVE
1. Spool Function
2. Upper cylinder • This valve operates the front brake depending on
3. Lower cylinder the parking brake release pressure controlled by
4. Spool the 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

(10)
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 {145 kg/cm2}
PP : From accumulator • Cut out pressure: 20.6 MPa {210 kg/cm2}
T : To transmission oil pan
H1 : Relief valve Function
R1 : Relief valve • The accumulator charge valve is actuated to
R3 : Main relief valve 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

(10)
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 Specifications
2. Check valve Piston operation pressure:
3. Piston 9.8 – 19.6 kPa {0.1 – 0.2 kg/cm2}
Check valve cracking pressure
A : Inlet port (When cooling pressure is 0):
B : Outlet port 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2}
Check valve closing pressure:
1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}
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

(10)
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

Wear of pad (remaining thick-
4
ness of wear material) 19.5 3.0
Replace
5 Missing portion of pad – Ratio of surface: 10%
Co r re c t o r
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

(9)
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

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
Distortion of disc friction Standard distortion Repair limit

17
surface Max. 0.45 0.7
Distortion 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

(10)
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 ac-
cumulator and the slack adjuster in the brake cir-
A : To slack adjuster cuit.
P : From accumulator 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

(10)
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 of
brake will operate the parking brake.
10-84 HD465-7, HD605-7

(10)
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
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
1. Cross-over relief valve

2. Steering cylinder
3. Hydraulic pump (SAR(3)80+80+(1)6)
4. Demand valve
5. Hoist valve
6. Hoist cylinder
7. Hydraulic tank
8. Steering hoist filter
9. Steering control valve
HD465-7, HD605-7 10-87

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 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 lever is controlled by
6. Hoist cylinder 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

(10)
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 STEERING CONTROL VALVE
STEERING CONTROL VALVE
1. Input shaft 8. Ball a : From demand valve (P port)

2. Upper cover 9. Torsion bar b : To tank (R port)
3. Valve spool 10. Link c : To steering cylinder (RT port)
4. Housing 11. Sleeve d : To hoist valve (AUX port)
5. Ball 12. Rotor e : To steering cylinder (LT port)
6. Stator 13. Manifold
7. Lower cover 14. Commutator
10-92 HD465-7, HD605-7

Operation
1. when steering is at neutral
• The oil from the pump passes through the

demand valve and enters port A of the steering
valve.
When this happens, the steering is at neutral, so
valve spool (3) does not move. As a result, all
ports to the steering cylinders are closed, and no
oil flows to the cylinders.
Ports H and J, and port I are open, so the oil
from the pump all flows to the hoist control valve.
HD465-7, HD605-7 10-93

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

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CROSSOVER RELIEF VALVE
CROSSOVER RELIEF VALVE
SC1 : To steering cylinder 1. Valve body

SC2 : To steering cylinder 2. Valve seat
SC3 : To steering cylinder 3. Relief valve
SC4 : To steering cylinder 4. Valve spring
SV1 : To steering valve 5. Sleeve
SV2 : To steering valve 6. Adjustment screw
7. Lock nut
10-96 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm

Tolerance Standard
Clearance between piston rod Shaft Hole clearance Replace
1
and bushing bushing
–0.030 +0.163 0.036 –
55 0.567
–0.104 +0.006 0.267
Clearance between piston rod +0.039

2 45 – – 1.0
supports shaft and bushing 0
Clearance between cylinder Replace

+0.039
3 bottom support shaft and bush- 45 – – 1.0
0
ing
HD465-7, HD605-7 10-97

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DEMAND VALVE
DEMAND VALVE
10-98 HD465-7, HD605-7

P1 : From hydraulic pump

P2 : From hydraulic pump
PH : To hoist control valve
PE : From emergency steering pump
PT : To tank
PST: To steering control valve
1. Spool return spring

2. Demand spool
3. Check valve
4. Check valve spring
5. Valve body
6. Main relief valve
7. Main relief valve spring
8. Pilot poppet
9. Pilot poppet spring
10. Lock nut
11. Adjustment screw
Unit: mm

Free length x Installed

12 Spool return spring O.D length
130.4 N 120.6 N Replace

172.2 x 29.7 140 –
{13.3 kg} {12.3 kg}
3.4 N 3.1 N
13 Check valve spring 42.2 x 17 33.5 –
{0.345 kg} {0.315 kg}
HD465-7, HD605-7 10-99

(10)
Function circuit directly through the port D.

• This valve distributes oil which comes from the The whole oil of the steering pump and part
steering pump and from the work equipment of oil from the work equipment pump flow
pump , to the steering circuit and to the work into the steering circuit.
equipment circuit depending on the engine
speed (pump delivery).
Operation
1. When the engine runs at low speed
• Oil from the steering pump flows into port A.
Also, oil from the work equipment pump
flows into port B, but since the demand spool
(2) is closed, the oil pushes to open the
check valve (3) and flows into port A, and
merges with oil from the steering pump.
• At the same time, the oil flows also into port
C through the orifice a of the demand spool
(2).
• Therefore, oil from the steering pump and oil
from the work equipment pump flow into the
steering control valve.
3. When the engine runs at high speed

• In addition, oil from the steering pump and oil
from the work equipment pump flow into port
A and port B.
• Therefore, the pressure at port C rises more
and moves the demand spool (2) further to
the right.
• The whole oil of the work equipment pump
and part of oil of the steering pump flow into
the work equipment circuit.
2. When the engine runs at medium speed

• Oil from the steering pump flows into port A.
Also, oil from the work equipment pump
flows into port B, pushes to open the check
valve (3), flows into port A and merges with
the oil from the steering valve.
• When the oil pressure to the steering circuit
rises, the pressure of the oil entered into port
C through the orifice a of the demand spool
(2) rises as well.
• When the pressure of port C increases more
than the force of the spring (1), the demand
spool (2) will be pushed to the right and port
B and port D will open.
• Therefore, part of the oil from the work equip-
ment pump flows into the work equipment
10-100 HD465-7, HD605-7

STEERING RELIEF VALVE

• When the pressures in port A and port B balance
with the poppet spring force (set pressure), the
pilot poppet (3) will open. Oil in port B will
escape through port D to port C, and the pres-
sure in port B will lower.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
• When the pressure in port B lowers, the orifice of

Function the main valve (1) generates a differential pres-
• This valve is located in the demand valve and sure between ports A and B, and the pressure in
release oil from the pump to prevent the pump port A pushes to opens the main valve (1) to
from being damaged when the steering cylin- release oil from port A.
der comes to the stroke end, or when an abnor-
mal pressure occurs. (This valve sets the
maximum pressure of the circuit.)
Operation
• Port A is connected to the pump circuit, and
port C is connected to the tank drain circuit.
• Oil flows through the orifice of the main valve
(1), and port B is filled with oil.
• Also, the pilot poppet (3) is seated to the valve
seat (2).
HD465-7, HD605-7 10-101

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

T : To tank
P : From flow amplifier
A1 : To hoist cylinder bottom
B1 : To hoist cylinder head
PA : From EPC valve (pressurized side in lowering or floating operation)
PB : From EPC valve (pressurized side in lifting operation)
1. Body
2. Spool
3. Retainer
4. Spring (lifting)
5. Relief valve
6. Spring (floating)
7. Spring (lowering)
8. Retainer
9. Retainer
10. Retainer
11. Check valve
Unit: mm

Free length Installed

12 Relief valve poppet spring × O.D. length
259 N 233 N
49.3 × 12.8 41.9
{26.4 kg}
–
{23.8 kg}
If damaged
44 N 40 N or defor-
13 Check valve spring 32.6 × 10.9 24.5
{4.5 kg}
–
{4.1 kg} mated,
replace the
156 N 140 N
14 Spool return spring (lifting) 51.3 × 34.5 50
{15.9 kg}
–
{14.3 kg}
spring
124 N 112 N
15 Spool return spring (lowering) 34.2 × 28.7 32
{12.7 kg}
–
{11.4 kg}
927 N 849 N
16 Spool return spring (floating) 74.0 × 36.0 55.5
{94.5 kg}
–
{85.1 kg}\
HD465-7, HD605-7 10-103

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

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

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

(10)
4. Hoist valve at LOWER Position
• When the hoist lever in the cab is set from the • On the other hand, the return oil from the head
FLOAT position to the LOWER position, pressur- side of the hoist cylinder flows out of chamber A
ized oil from the solenoid valve pushes the hoist and flows into chamber H.
spool (2) to the right further from the FLOAT • At the time of lowering, the output pressure of
position. Therefore, oil from chamber C pushes the solenoid valve rises over the cracking pres-
to open the check valve (11) and flows into sure of the pilot check valve, and therefore, the
chamber B. return oil from chamber H returns through cham-
• Then, oil flows into the head side of the hoist cyl- ber D to the tank.
inder through chamber B, retracts the hoist cylin-
der and lowers the body.
HD465-7, HD605-7 10-107

(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EPC VALVE
EPC VALVE
1. Manual operation button Function

2. Solenoid assembly • The EPC valve controlled by the retarder control-
3. Solenoid assembly ler switches the pilot pressure of the hoist valve,
and controls pressure, and controls the hoist
A : To hoist valve valve.
B : From hoist valve
P1 : From hydraulic tank
T1 : To hydraulic tank
T2 : To hydraulic tank
10-108 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOIST CYLINDER
HOIST CYLINDER
Unit: mm

Tolerance Standard
Clearance between cylinder and Shaft Hole clearance
1
bushing
–0.043 +0.264 0.089 –
170 0.707
–0.143 +0.046 0.407
Clearance between piston rod –0.036 +0.207 0.103 – Replace

2 100 0.693
and bushing –0.123 +0.067 0.393
Clearance between piston rod +0.004

3 70 – – 1.0
support pin and bushing –0.019
Clearance between cylinder sup- +0.004

4 70 – – 1.0
port pin and bushing –0.019
HD465-7, HD605-7 10-109

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING, HOIST AND HOIST CONTROL PUMP
SAR(3)80+80+(1)6
Unit: mm

Model Standard clearance Clearance limit
SAR(3)-80
1 Side clearance 0.10 – 0.15 0.19
SAR(3)-80
SAR(1)-6 0.10 – 0.15 0.19
Clearance between inside SAR(3)-80
diameter of plain bearing and 0.060 – 0.149 0.20
2 SAR(3)-80
outside of diameter of gear Replace
shaft SAR(1)-6 0.06 – 0.144 0.20
Model Standard size Tolerance Repair limit
SAR(3)-80 0
13
3 Depth to knock in pin SAR(3)-80 –0.5
–
0
SAR(1)-6 10
–0.5
4 Rotating torque of spline shaft 15.8 – 28.5 Nm {1.6 – 2.9 kgm}
Standard
Rotating Delivery pres- Delivery
delivery
Model speed sure amount limit
amount
Discharge amount (rpm) MPa {kg/cm2} ( /min)
( /min) –
– Oil: EO10-CD
Oil temperature: 45–55°C SAR(3)-80
184 170
SAR(3)-80 2,500 20.6 {210}
SAR(1)-6 13.2 12.6
10-110 HD465-7, HD605-7

(10)
RETARDER COOLING PUMP

SAR(3)100+100
Unit: mm
Clearance between gear case Model Standard clearance Clearance limit

1
and side plate, gear SAR(3)-100 0.13 – 0.18 0.22
Clearance between inside

2 diameter of plain bearing and SAR(3)-100 0.06 – 0.149 0.20
outside diameter of gear shaft
Replace
3 Depth to knock in pin 0
SAR(3)-100 14 –
–0.5
Rotating torque of splined

4 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
shaft
Standard
Rotating Delivery
Delivery delivery
Delivery amount Model speed amount limit
pressure amount
– Oil: EO10-CD (rpm) ( /min.) –
( /min.)
Oil temperature: 45 – 55°C
3.9 MPa
SAR(3)-100 2,500 236 216
{40 kg/cm2}
HD465-7, HD605-7 10-111

TORQUE CONVERTER, TRANSMISSION, RETERDER COOLING AND BRAKE PUMP

SAR(3)100+(1)25
Unit: mm

1 Side clearance SAR(3)-100 0.13 – 0.18 0.21
SAR(1)-25 0.10 – 0.15 0.19
Clearance between inside SAR(3)-100 0.06 – 0.149
diameter of plain bearing and
2 0.20 Replace
outside of diameter of gear SAR(1)-25 0.06 – 0.144
shaft
Model Standard size Tolerance
3
Depth to knock in pin SAR(3)-100 14 0
–
4 SAR(1)-25 10 –0.5
5 Rotating torque of spline shaft 8.9 – 16.7 Nm {0.9 – 1.7 kgm}
Standard
Rotating Delivery pres- Delivery
delivery
Model speed sure amount limit
Discharge amount amount –
– Oil: EO10-CD (rpm) MPa {kg/cm2} ( /min)
( /min)
Oil temperature: 45–55°C
SAR(3)-100 20.6 {210} 231.5 213.5
2,500
SAR(1)-25 20.6 {210} 57.0 50.7
10-112 HD465-7, HD605-7

(10)
EMERGENCY STEERING PUMP

SBL(1)-014
Unit: mm

1 Clearance between gear case
and side plate, gear SBL(1)-014 0.10 – 0.15 0.19
Clearance between inside

2 diameter of plain bearing and SBL(1)-014 0.06 – 0.119 0.20
outside diameter of gear shaft
Replace
3 Depth to knock in pin 0
SBL(1)-014 10 –
–0.5
Rotating torque of splined

4 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
shaft
Standard
Rotating Delivery
Delivery delivery
Delivery amount Model speed amount limit
pressure amount
– Oil: EO10-CD (rpm) ( /min.) –
( /min.)
Temperature: 45 – 55°C
20.6 MPa
SBL(1)-014 3,500 45.7 42.4
{210 kg/cm2}
HD465-7, HD605-7 10-113

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
1. Receiver dryer Heating

2. Air conditioner unit • Heating is carried out using the coolant from the
3. Compressor engine.
4. Condenser High-temperature coolant from the hot water take-
off port flows to the air conditioner unit, and hot air
is blown out by a fan.
When the temperature of the coolant drops, it is
returned to the hot water return port and flows as
coolant for the engine.
Function Cooling
• The air conditioner makes a pleasant operating • The refrigerant gas compressed and pressurized
environment for the operator and acts to reduce by the air conditioner compressor enters the air
fatigue. conditioner condenser where it is cooled by dis-
sipating the heat It then enters the air conditioner
unit and cold air is blown out by the fan. When
the temperature of the refrigerant gas rises, it is
returned to the compressor.
10-114 HD465-7, HD605-7

(10)
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper

2. Evaporator
3. Heater core
4. Blower motor
A : Hot water inlet port

B : Hot water outlet port
C : Refrigerant gas inlet port
D : Refrigerant gas outlet port
E : Dehumidified water drain port
HD465-7, HD605-7 10-115

(10)
RECEIVER DRYER
1. Body
2. Dryer
10-116 HD465-7, HD605-7

CONDENSER
1. Fin
2. Tube
A : Refrigerant gas inlet port

B : Refrigerant gas outlet port
HD465-7, HD605-7 10-117

COMPRESSOR
1. Case
2. Clutch
A : Suction service valve

B : Discharge service valve
10-118 HD465-7, HD605-7

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. ECMV 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 machine monitor system consists of the
• Gauges (engine water temperature, monitor panel, buzzer, and switches, network,
torque converter oil temperature, retarder controllers on the network, and the sensors
oil temperature, fuel level) inputting data to the monitor panel.
• Pilot display
• Service meter, odometer (character dis- • If the payload meter (having VHMS) is set
play) optionally, execute display of load mass and set-
2. Items displayed when there is abnormality ting of items related to the payload meter, too.
Caution, action code display (if an action code For details, see "OPERATION AND MAINTE-
is being displayed, press machine monitor NANCE MANUAL" and "STRUCTURE, FUNC-
mode selector switch (2), then release it. A TION AND MAINTENANCE STANDARD, Payload
failure code (6-digit) is then displayed.) meter (having VHMS)".
3. When the filter, oil replacement interval is
reached, the item needing replacement is
displayed in the character display.
4. Other functions using the character display
and the machine monitor mode selector
switch to operate include the following: Total
reverse distance traveled display, filter, oil
replacement interval reset, telephone num-
ber input, and language selection.
• To make it easier to carry out troubleshooting of

the controllers (including the monitor panel
itself), a service mode function is provided. Its
main content is as follows.
1. Displaying failure history for electrical sys-
tem, deleting from memory
• Displays failure history for electrical sys-
tem from each controller that is saved in
machine monitor
• Deletes data from memory
2. Failure history for machine system
• Displays failure history for machine sys-
tem from each controller that is saved in
machine monitor
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

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MACHINE MONITOR
1. Speedometer 24. Seat belt caution lamp

2. Engine tachometer 25. Body caution lamp
3. Retarder oil temperature gauge 26. Emergency steering pilot lamp
4. Torque converter oil temperature gauge 27. Turn signal pilot lamp (right)
5. Coolant temperature gauge 28. Turn signal pilot lamp (left)
6. Fuel gauge 29. Headlamp highbeem pilot lamp
7. Character display 30. Shift lever position pilot lamp
8. Centralized warning lamp 31. Shift indicator
9. Retarder oil temperature caution lamp 32. Retarder pilot lamp
10. Torque converter oil temperature caution lamp 33. Lockup pilot lamp
11. Coolant temperature caution lamp 34. Output mode pilot lamp (power mode)
12. Fuel level caution lamp 35. Output mode pilot lamp (economy mode)
13. Maintenance caution lamp 36. Suspension mode pilot lamp (hard) (if equipped)
14. Battery charging circuit caution lamp 37. Suspension mode pilot lamp (medium)
15. Steering oil temperature caution lamp (if equipped)
(if equipped) 38. Suspension mode pilot lamp (soft) (if equipped)
16. Engine oil pressure caution lamp 39. ABS pilot lamp (if equipped)
17. Retarder oil pressure caution lamp 40. ASR pilot lamp (if equipped)
18. Parking brake caution lamp 41. Preheater pilot lamp
19. Machine monitor option system caution lamp 42 Automatic retarder READY pilot lamp
20. Engine system caution lamp 43. Automatic retarder set speed indicator
21. Transmission system caution lamp 44. Automatic retarder set speed unit indicator (km/h)
22. Retarder system caution lamp 45. Automatic retarder set speed unit indicator (MPH)
23. Inclination caution lamp
HD465-7, HD605-7 10-121

(10)
41. Travel speed compensation switch [SW1]

42. Rotary switch [SW2]
43. Rotary switch [SW3]
44. Dipswitch [SW5-4]
51. Dipswitch (SW6-1]
10-122 HD465-7, HD605-7

OPTION SETTING CONNECTOR DIAGRAM
52. Option setting connector [OP1]

58. Setting connector [OP7]
ADJUSTING MACHINE MONITOR

1. For details of the setting of the rotary switches,
the switches, and options setting connectors at
the rear face of the machine monitor, see TEST-
ING AND ADJUSTING, Adjusting machine moni-
tor.
2. Precautions
1) When setting, follow the instructions in TEST-
ING AND ADJUSTING, Adjusting machine
monitor, and do not change them.
2) When moving the switches, use a precision
screwdriver and turn slowly.
3) Be careful not to touch anything except the
switches inside the grommet.
4) Be careful not to let any dirt or dust get in.
5) After completing the setting, return the grom-
met securely to its original position.
HD465-7, HD605-7 10-123

MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
: Lighted up : Discontinuous sounds

✩1: The mark shows that the light is lit up while the machine monitor check switch is ON.
✩2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
Related ✩1
operation When ✩2
machine Immedi-
Display Display Display range/ Display Central Warn- monitor ately
No. item category Device Color conditions method check after Remarks
warning switch is turning
ing buzzer oper- key ON.
lamp
ated.
Note: When operating

the machine
Scale: 0 – 80 km/h or monitor check
white 0 – 50 MPH switch, turn switch
Meter Move- Back- (MPH is dis- Analog — — — knob back and
ment ground played when non- display (Note) forth one time, as
Machine color: starting from the
1 speed SI is used.)
black current position
and return to the
starting position.
When the Lit up during

Backlight LED Amber small lamp is operation — —
lit up.
Analog display Note: When operating

the machine
Scale: * When the monitor check
white, red overrun pre- switch, turn switch
Move- Back- vention brake knob back and
Meter 0 – 3,400 rpm is operated, —
ment ground (Note) forth one time, as
Engine color: the buzzer and starting from the
2 speed central warn-
ing lamp is and return to the
lit up. starting position.

Backlight LED Amber small lamp is operation — —
lit up.

the machine
Scale: monitor check
white, red switch, turn switch
Move- Back- 50 – 150°C Analog knob back and
Gauge ment ground (120°C or higher display — — — forth one time, as
in the red zone) (Note)
Oil tem- color: starting from the
3 perature black current position
9 of and return to the
retarder starting position.
At 120°C Lit up during

Warning LED Red or higher warning
When the
Backlight LED Amber small lamp is Lit up during — —
lit up. operation.

the machine
Move- Back- 50 – 135°C Analog knob back and
Gauge ment ground (120°C or higher display — — — forth one time, as
color: in the red zone) (Note)
Oil tem- starting from the
4 perature
10 of torque and return to the
converter starting position.
Warning LED Red At 120°C Lit up during

or higher warning
Backlight LED Amber small lamp is operation.  
lit up.
10-124 HD465-7, HD605-7

(9)
Related When
operation machine Immedi-
Display Display Display range/ Display monitor ately
Central switch is
warn- Warn- oper- turning
ing ing key ON.
ated.
lamp buzzer
the machine
white, red 50 – 135°C switch, turn switch
Gauge Move- Back- (102°C or higher Analog — — — knob back and
ment ground in the red zone) display (Note) forth one time, as
Engine color: starting from the
5 coolant black current position
tempera- and return to the
11 ture starting position.
Warning LED Red At 102°C or Lit up during

higher warning
Backlight LED Amber small lamp is operation. — —
lit up.
the machine
Gauge Move- Back- EMPTY – FULL Analog — — — knob back and
ment ground display (Note) forth one time, as
color: starting from the
6 Fuel and return to the
12 level starting position.
Specified level
or less
(remaining quan- Lit up during
Warning LED Red operation — —
tity in the tank at
120 or less)
When the small Lit up during
Backlight LED Amber lamp is lit up. operation. — —
0 – 65535.0h Operates
Service when the
meter Service * Displayed in the engine is When 65535.0h is
(Regular meter "upper column" running. — — exceeded, fixed at
display on the character 1:1 against 65535.
item) display clock time
Odome-
ter * Displayed in When 999999.9 km is
(Regular Odometer the "lower col- Operates dur- — — exceeded, fixed at
display umn" on the char- ing traveling. 999999.9 km.
item) acter display
When any
problem or Note 1:"HD-465" is dis-
When any prob- failure occurs,
lem or failure played in the
Display the action upper column.
character: occurs on the code is dis- Note 2: "KOMATSU" is
Action Action black machine, * Dis- played in the — — Note 1 Note 2 displayed in the
7 code code LCD Back- played in the upper column upper column
ground upper and lower and remedies and "SYSTEM
color: columns on the or description CHECK" in the
green character display. of problem in lower column.
the lower col-
umn.
Press machine The failure

monitor mode code
selector switch > (6 digits) and
during the occur- detection
rence of the prob- controller are For information on how
Failure Failure lem or displayed in to operate display, see
code code failure on the the upper col- — — the Operation & Main-
machine. umn and the tenance Manual.
faulty system
* Appears in the or description
upper and lower of problem in
columns on the the lower
character display. column.
HD465-7, HD605-7 10-125

(10)
Related When
Central switch is turning
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Reverse
travel
integrating
meter Display Switch screen
Reset of character: Press machine by operating
time to black monitor mode machine For details, see the
Other selector switch
displays change fil- LCD Back- monitor mode Operation & Mainte-
ter and oil. ground " " selector nance Manual.
Telephone color: switch
7 number green ">" or "<".
setting
Language
selection
Dimmed down
Night When the by a step
lighting Backlight LED Green small lamp is when the — —
lit up. small lamp is
lit up.
Central During system is Lit up during
8 warning LED Red abnormal warning.
lamp
Note 1:The moment
when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
Mainte- nance-related has been given
13 nance LED Red alarm is given or Lit up or turn — — appear on the
warning the time to ON and OFF character
change filter and display.
oil has elapsed. Note 2:For details on
the target items,
etc., see the
Operation &
Maintenance
Manual.
Battery
During battery
charging Lit up during
14 LED Red charging circuit
circuit warning.
being abnormal
warning
Steer-
ing oil When the
tempera- Warning steering oil Lit up during
15 LED Red
ture temperature warning.
warning rises.
(option)
Engine
When the engine
oil pres- Lit up during
16 LED Red oil pressure
sure warning.
drops.
warning
Retarder When the
Lit up during Operates when the
oil pres- retarder
17 LED Red being abnor- alternator R terminal is
sure oil pressure (Note) (Note)
mal. ON.
warning drops.
Operates when the
Parking When the parking brake is oper-
Lit up during
18 brake LED Red parking brake is ated and the shift lever
operation. (Note) (Note)
warning operated. is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up during tions, used in the event
19 LED Red machine monitor
optional warning. of failure of the
or optional
system machine monitor.
controller system
warning
During being
Engine
abnormal in Lit up during
20 system LED Red
engine control warning.
warning
system.
10-126 HD465-7, HD605-7

(10)
Related When
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Trans-
Being abnormal
mission Lit up during
21
system
LED Red in transmission
warning.
control system
warning
During being
Retarder
abnormal in Lit up during
22 system LED Red
retarder control warning.
warning
system
When the body is
Inclina-
lifted and inclined Lit up during
23 tion LED Red
excessively warning.
warning Warning from side to side.
During
operation:
Seat-
When the seat- lit up
24 belt LED Red — —
belt is not worn. During non-
warning
operation:
turned OFF.
During
See the operation: Note: Operates when
Body lit up the shift lever is in
25 LED Red instruction
warning manual During non- (Note) (Note) other than the "N"
operation: position.
turned OFF.
During
Emer- When the emer- operation:
26 gency LED Red gency steering is lit up  
steering operated. During non-
operation:
turned OFF.
During
Turn operation:
lit up
27 signal, LED Green During operation During non- — —
right operation:
turned OFF.
During
Turn operation:
lit up
28 signal, LED Green During operation During non- — —
left operation:
turned OFF.
During
Head- operation:
light, lit up
29 LED Blue During operation During non- — —
high
beam Pilot operation:
turned OFF.
Shift
30 When the shift
lever
LED Green lever is in the "R" Lit up (*) — — * Blinks when the neu-
(R) position position tral safety is operated.
R
Shift
30 When the shift
lever
LED Orange lever is in the "N" Lit up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lit up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift
lever
LED Green lever is in the "6" Lit up (*) — — * Blinks when the neu-
(6) position tral safety is operated.
position
6
Shift
30 When the shift
lever
(5) position tral safety is operated.
position
5
HD465-7, HD605-7 10-127

(9)
Related opera- When

tion machine Immedi-
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Shift
30 When the shift
lever
(4) position position tral safety is operated.
4
Shift
30 lever
When the shift * Blinks when the neu-
LED Green lever is in the "3" Lit up (*) — — tral safety is operated.
(3) position position
3
Shift
30 lever
LED Green lever is in the "2" Lit up (*) — — tral safety is operated.
(2) position position
2
Shift
30 lever
LED Green lever is in the "L" Lit up (*) — — tral safety is operated.
(L) position position
L
Pilot
F1, F2, F3, F4,
F5, F6, F7, N, R
* According to
the gear shift
signal received
from the When the
transmission gear shift
Back- controller. range
Shift
LCD
ground * When an alarm signal is
  All lit All lit
indicator color: is raised in the received
gray from the up. up.
31 event of
emergency transmission
escape, "E-" and controller.
the
"gear speed
range" are alter-
natively
displayed.
When the During
Night
Backlight LED Amber small lamp is operation: — —
lighting
lighted up. lit up
During
operation:
When the
lit up
32 Retarder LED Orange retarder brake is — —
During non-
operated.
operation:
turned OFF
During
When lockup of
operation:
the torque con-
lit up
33 Lockup LED Green verter is activated — —
During non-
and direct drive is
operation:
effective
turned OFF
High-power
mode
Output
in operation:
mode At high-power
34 Pilot LED Green lit up — —
(power mode
During non-
mode)
operation:
turned OFF
Economy
Output mode
mode in operation:
At economy
35 (econ- LED Green lit up — —
mode
omy During non-
mode) operation:
turned OFF
Sus-
pension
At suspension Lit up in
36 mode LED Green — —
"hard" mode "hard" mode
(hard)
(option)
10-128 HD465-7, HD605-7

(9)
Related opera- When

tion machine Immedi-
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Suspen-
sion
Lit up in
mode In suspension
37 LED Green "medium" — —
(medium) "medium" mode
mode
(if
equipped)
Suspen-
sion
In suspension Lit up in "soft"
38 mode LED Green — —
"soft" mode mode
(soft) (if
equipped)
During
operation:
When ABS is
ABS (if lit up
39 LED Orange operated. — —
equipped) During non-
operation:
turned OFF
During
operation:
When ASR is
ASR (if lit up
40 LED Orange operated.
equipped) During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lit up
41 LED Red for preheating — —
ing During non-
Pilot engine is
operation:
operated.
turned OFF
Auto-
When ready
matic When automatic
to be
42 retarder LED Green retarder is ready — —
operated:
being to be operated.
lit up
ready
Auto-
Back-
matic
ground
When automatic Display of set * Zero is displayed
43 retarder LCD retarder switch is — — when the set speed is
set
color: turned ON. speed (*)
gray cancelled.
speed
Auto- During
When automatic
matic operation:
retarder switch is
retarder lit up
44 LED Green turned ON and — —
unit During non-
the unit km/h is
display operation:
selected.
(km/h) turned OFF
auto- During
When automatic
matic operation:
retarder switch is
retarder lit up
45 LED Green turned on and the — —
display During non-
unit km/h is
unit operation:
selected.
(MPH) turned OFF
HD465-7, HD605-7 10-129

(10)
Self-diagnostic function when operating starting

switch
1. When the starting switch is turned to the ON
position before starting the engine, the system
check is carried out for 3 seconds.
2. If the starting switch is turned to the START posi-
tion before 3 seconds have passed with the start-
ing switch at the ON position, everything will go
to the normal operating condition. However, even
if everything goes to the normal operating condi-
tion, the indicator gauges and meters will not
work until 3 seconds have passed after the start-
ing switch was turned to the ON position.
Check function of central warning lamp, alarm

buzzer, monitor lamps, and meters
To check the normal display function of the machine
monitor, press the machine monitor check switch to
check the actuation. For details of the actuation, see
"When operating machine monitor normal display
functions with machine monitor check switch".
10-130 HD465-7, HD605-7

OUTLINE OF SERVICE MODE

1. Outline
1) Failure history for electrical system
The system is used to check the failure his-
tory for the electrical system of each control-
ler saved in the machine monitor. For details
of the failure codes displayed for the failure
history of the electrical system, see the trou-
bleshooting section. After repairing the fail-
ure, check that the system works properly,
then delete the failure history.
The failure history display for the electrical
system is displayed on the character display
as shown below.
*** : Displays order of failure history items
###### : Displays failure code
$$$ : Displays number of times that applicable
failure code has occurred
%%%%% :Displays time that has elapsed
since failure first occurr ed
(Present service meter reading -
Service meter reading when
problem first occurred = Time
elapsed)
@@@@@ : Displays time that has elapsed
s i nc e fa i l ur e l a s t o c c ur r ed
(Present service meter reading
- Service meter reading when
problem last occurred = Time
elapsed)
The failure code flashes for failures that are
still occurring at present.
The number of times that the failure code for
the machine system has occurred is saved in
memory.
2) Failure history for machine system
The system is used to check the failure his-
tory for the machine system of each control-
ler saved in the machine monitor. For details
of the failure codes displayed for the failure
history of the machine system, see the trou-
bleshooting section. After repairing the fail-
ure, check that the system works properly,
then delete the trouble data.
The failure history display for the machine
system is displayed on the character display
as shown below.
*** : Displays order of failure history items
###### : Displays failure code
$$$ : Displays number of times that applica-
ble failure code has occurred
%%%%% : Displays time that has elapsed
since failure first occurred
HD465-7, HD605-7 10-131

(10)
@@@@@ : Displays time that has elapsed

since failure last occurred
The failure code flashes for
failures that are still occurring
at present. The number of
times that the failure code for
the machine system has
occurred is saved in memory.
3) Real-time monitor
This function is used when checking the
input and output signals recognized by the
controllers on the network.
The real-time monitor display on the charac-
ter display is as shown right.
*** : Displays name of item
##### : Displays ID No. given to each item
%%% : Displays data. If units are used, the
unit is displayed on the right side of
the data By specifying the ID No.
given to each item, it is possible to
display the desired 2 items at the
same time. The character display
when a second item is displayed at
the same time is as shown right
##### : Displays specified ID No.
%%% : Displays data. If units are used, the-
unit is displayed on the right side of
the data
4) ECMV compensation
For details of this function, see TESTING
AND ADJUSTING, SPECIAL FUNCTIONS
OF MACHINE MONITOR.
5) Changing filter, oil replacement time
For details of this function, see the Operation
and Maintenance Manual, OPERATION,
Character display portion, Filter, oil 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, FUNCTION
AND MAINTENANCE STANDARD, Payload
meter (having VHMS)".
8) Controller initialize
This function is used only at the factory, so
do not touch it.
10-132 HD465-7, HD605-7

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2. Method of operation
For details of the method of operating each ser REMARK : When the starting switch is turned OFF, it
vice mode function, see TESTING AND ADJUST- returns to the normal mode.
ING SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
HD465-7, HD605-7 10-133

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

SYSTEM DRAWING
10-134 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
• With the control system using engine controller,

the signals detected by the sensers are input
and the engine controller calculates these. It
then outputs the signal for the results to the actu-
ators to control the fuel injection amount and the
fuel injection timing.
• The machine monitor stores data transmitted

from engine controller, as common data.
AISS (Automatic Idle Setting system)
Outline
• The AISS is a system which sets the engine low
idle speed at manual or automatic to two levels
according to the operating conditions of the
machine.
In this way it is possible to imoprove the fuel con-
sumption and the starting and acceleration abil-
ity.
Set idle speeds
Low idle speed : 750 rpm
High idle speed : 945 rpm
High, low speed set conditions
Operating High/low
Conditions
methods category
Set to low position Manual
Engine coolant temperature

above 50°C and parking brake Automatic
Low
applied
speed
Engine coolant temperature
above 50°C and retarder lever Automatic
actuated
Engine coolant temperature less

Automatic
than 50°C High
Parking brake released and speed
Automatic
retarder lever not actuated
HD465-7, HD605-7 10-135

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
10-136 HD465-7, HD605-7

Outline
• The transmission controller receives the shift
position signal for the gearshift lever, the acceler-
ator signal for the accelerator pedal, the speed
signal for the transmission, and the other signals
from the switches and sensors. It then automati-
cally controls the transmission and shifts it to the
optimum speed range.
• In addition to the shift control, the transmission
controller also controls the torque converter lock-
up solenoid and operates the brake to prevent
overrun.
Each clutch pack of the clutch packs and torque
converter lock-up clutch in the transmission is
equipped with an electronically controlled modu-
lation valve, and each clutch pack is indepen-
dently controlled.
In this way, the initial pressure, build-up ratio,
and torque-off time for each clutch is controlled
according to the condition of the machine. This
reduces the gearshifting shock and prevents shift
hunting, and in this way contributes to improv-
ing the durability of the clutches.
• The transmission shift controller uses the signals
from the switches and sensors to drive the
machine monitor displays and caution and pilot
lamps, and transmits these data to the network.
HD465-7, HD605-7 10-137

TRANSMISSION CONTROLLER
1. Self-diagnostic display window 5. Speed sensors are installed at three places

2. Connector (transmission input shaft, intermediate shaft,
3. Case and output shaft). This makes it possible to
4. Motherboard detect slippage of the transmission clutches
5. Model selector switch (rotary switch 1) and to protect the transmission when there is
6. Model selector switch (rotary switch 2) any abnormality in the hydraulic system.
6. It connects to the network and shares vari-
Outline ous data with other controllers.
• The transmission controller controls the trans- 7. It receives input of the model selection data
mission system. (what model it is mounted on), and uses the
It has the following features and functions. network to contact other controllers. (For
1. It has a high power mode and economy details of the method of setting, see TESTING
mode, and the gearshifting pattern can be AND ADJUSTING, AND TROUBLESHOOT-
selected. ING.)
2. The braking mode is the mode when the 8. It has a self-diagnostic function which divides
brake is used. By raising the gearshifting the input and output systems further into
point and increasing the speed of the brake small parts.
cooling pump, it is possible to raise the cool- 9. The self-diagnostic function is displayed in
ing effect of the retarder and make effective two digits.
use of the engine brake. 10. When an abnormality is detected, it transmits
3. It controls the torque converter lock-up sole- the details to the network and displays it on
noid valve and overrun prevention brake. the other displays.
4. To reduce the shock when shifting gear, it 11. It uses the machine monitor to display if the
outputs the throttle correction command to failure is still existing.
the engine controller when shifting gear and 12. It provides an escape function for use when
limits the engine speed. there is a failure in the electrical system.
10-138 HD465-7, HD605-7

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CN1 (MIC 17-POLE) Machine Connector Number : ATC1_MIC

Pin Specification Signal name Remarks
No.
1 ON/OFF OUT (POWER) 0 N.C
Power output (+24V) for torque converter oil
3 ON/OFF OUT (POWER) 4 POWER SUPPLY (+24V) FOR T/C
pressure sensor
Power input (+24V) for overrun prevention
4 ON/OFF OUT (POWER) 6H POWER INPUT (+24V) FOR OVERRUN
brake output
Power input (+24V) for transmission cut relay
5 ON/OFF OUT (POWER) 7H POWER INPUT (+24V) T/M CUT RELAY
output
6 ON/OFF OUT (SIG) 8 Droop mode output 3 (Idling controll) DROOP MODE OUT 3 FOR ENG
7 Battery direct power supply (+24V) Battery direct power supply (+24V) BATTERY DIRECT (+24V)
8 Controller power supply (GND) GND INPUT GND
9 Controller power supply (+24V) Power supply voltage (+24V) POWER INPUT (+24V)
13 ON/OFF OUT (POWER) 6L Overrun prevention brake output command OVERRUN OUT
14 ON/OFF OUT (POWER) 7L Transmission cut relay output T/M CUT RELAY
Droop mode output 2
15 ON/OFF OUT (SIG) 9 DROOP MODE OUT 2 FOR ENG
(Power/Economy selection)
16 Controller power supply (GND) GND INPUT GND
17 Controller power supply (+24V) Power supply voltage (+24V) POWER INPUT (+24V)
HD465-7, HD605-7 10-139

CN2 (MIC 21-POLE) Machine Connector Number : ATC2_MIC

Pin
No. Specification Signal name Remarks
1 SOL power supply (+24V) SOL power input (+24V) POWER INPUT (+24V) FOR SOLENOID
2 SOL_OUT 4A+ ECMV current output (+) "1st clutch" ECMV SOLENOID "1ST" (+)
3 SOL_OUT 4B+ ECMV current output (+) "4th clutch" ECMV SOLENOID "4TH" (+)
4 SOL_OUT 5A+ ECMV current output (+) "2nd clutch" ECMV SOLENOID "2ND" (+)
5 SOL_OUT 5B+ ECMV current output (+) "Rev clutch" ECMV SOLENOID "REV" (+)
6 A_OUT 0 N.C
7 SOL_OUT 0+ ECMV current output (+) "Low clutch" ECMV SOLENOID "LOW" (+)
8 SOL_OUT 1+ ECMV current output (+) "3rd clutch" ECMV SOLENOID "3RD" (+)
9 SOL_OUT 2+ ECMV current output (+) "High clutch" ECMV SOLENOID "HIGH" (+)
10 SOL_OUT 3+ ECMV current output (+) "lockup clutch" ECMV SOLENOID "L/U" (+)
11 A_OUT 1 N.C
12 SOL power supply (+24V) SOL power input (+24V) POWER INPUT (+24V) FOR SOLENOID
13 SOL_OUT 4A–, 4B– ECMV current output (–) "1st, 4th clutch" ECMV SOLENOID "1ST, 4TH" (–)
14 VDD_OUT (24V) N.C
15 SOL_OUT 5A–, 5B– ECMV current output (–) "2nd, Rev clutch" ECMV SOLENOID "2ND, REV" (–)
16 VDD_OUT (+5V) N.C
17 SOL_OUT 0– ECMV current output (–) "Low clutch" ECMV SOLENOID "LOW" (–)
18 SOL_OUT 1– ECMV current output (–) "3rd clutch" ECMV SOLENOID "3RD" (–)
19 SOL_OUT 2– ECMV current output (–) "High clutch" ECMV SOLENOID "HIGH" (–)
20 SOL_OUT 3– ECMV current output (–) "lockup clutch" ECMV SOLENOID "L/U" (–)
21 Power GND GND INPUT GND
10-140 HD465-7, HD605-7

CN3 (040 20+16-POLE) Machine Connector Number : ATCA_040, ATC3B_040

No.
1 CN_CHKO N.C
2 PULS INPUT 0 Transmission input shaft speed sensor TRANSMISSION INPUT SPEED
3 PULS INPUT 1 Transmission output shaft speed sensor TRANSMISSION OUTPUT SPEED
4 PWM_IN N.C
5 PULS OUTPUT Throttle modification signal output THROTTLE MODIFICATION
6 Sensor power supply (+5V) Potentio power supply SENSOR POWER SUPPLY (+5V)
7 Analog_INPUT 0(+) Torque converter oil pressure sensor TORQUE CONVERTER PRESS SENSOR
8 Analog_INPUT 1(+) N.C
TRANSMISSION OIL LEVEL SW
9 Analog_INPUT 2 Transmission oil level switch (if equipped)
(if equipped)
10 Analog_INPUT 3 Emergency escape signal LIMP HOME SW
11 ON/OFF INPUT 35 Steering oil temperature switch (if equipped) STEERING OIL TEMP SW (if equipped)
Transmission intermediate shaft speed sen-
12 PULS INPUT 2 TRANSMISSION MIDDLE SPEED
sor
13 PULS INPUT 3 Engine speed sensor ENGINE SPEED
14 PULS GND GND SPEED GND
15 PWM_OUT N.C
16 Analog GND GND for sensor ANALOG SENSOR GND
17 Analog_INPUT 0(–) GND (Analog GND is connected) INPUT ANALOG SENSOR GND
18 Analog_INPUT 1(–) N.C
19 Analog_INPUT 4 Air cleaner clogging switch AIR CLEANER SW
20 Analog_INPUT 5 N.C
21 Analog_INPUT 6 Alternator Terminal R voltage ALTERNATOR R
23 Analog_INPUT 8 Electrolyte level switch (if equipped) BATTERY LEVEL SW (if equipped)
24 Analog_INPUT 9 Fuel level sensor FUEL LEVEL
27 Analog_INPUT 12 Torque converter oil temperature sensor TORQUE CONVERTER OIL TEMP
29 Analog_INPUT 14 Transmission valve oil temperature sensor ECMV OIL TEMP
31 Analog_INPUT 16 Accelerator pedal signal ACCEL SIGNAL
HD465-7, HD605-7 10-141

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CN4 (040 12-POLE) Machine Connector Number : ATC4_040

No.
1 RS422 TX (+)
2 RS422 RX (+)
3 RS232C TXD —
4 RS232C RXD
5 RS485 (+)
6 S-NET (+) S-NET (+)
7 RS422 TX (–)
8 Flash write switch
9 RS422 RX (–)
10 RS232 C/S-NET GND S-NET GND
11 RS485 (–)
12 S-NET (+) S-NET (+)
10-142 HD465-7, HD605-7

CN5 (040 20+16-POLE) Machine Connector Number : ATC5A_040

No.
1 CN_CHKI GND INPUT GND
STEERING HOIST OIL TANK LEVEL
2 ON/OFF INPUT 0 Hydraulic tank level switch (option)
SWITCH (OPTION)
3 ON/OFF INPUT 1 Coolant level COOLANT LEVEL SWITCH
4 ON/OFF INPUT 2 N.C
6 ON/OFF INPUT 4 Transmission filter clogging switch TRANSMISSION FILTER SWITCH
7 ON/OFF INPUT 5 Engine oil level switch (option) ENG OIL LEVEL SWITCH (OPTION)
8 ON/OFF INPUT 6 Engine oil filter clogging switch (option) ENG OIL FILTER SWITCH (OPTION)
STEERING HOIST FILTER SWITCH
9 ON/OFF INPUT 7 Hydraulic oil filter clogging switch (option)
(OPTION)
10 ON/OFF INPUT 8 Fill switch signal "Low clutch" FILL SIGNAL "LOW"
11 ON/OFF INPUT 9 Fill switch signal "4th clutch" FILL SIGNAL "4TH"
12 ON/OFF INPUT 10 Fill switch signal "High clutch" FILL SIGNAL "HIGH"
13 ON/OFF INPUT 11 Fill switch signal "1st clutch" FILL SIGNAL "1ST"
14 ON/OFF INPUT 12 Fill switch signal "2nd clutch" FILL SIGNAL "2ND"
15 ON/OFF INPUT 13 Fill switch signal "3rd clutch" FILL SIGNAL "3RD"
16 ON/OFF INPUT 14 Fill switch signal "Rev clutch" FILL SIGNAL "REV"
17 ON/OFF INPUT 15 Fill switch signal "lockup clutch" FILL SIGNAL "L/U"
18 ON/OFF INPUT 16 Key C signal KEY SWITCH C
19 ON/OFF INPUT 17 Emergency steering operation signal 1 EMERGENCY STEERING RELAY 1
20 ON/OFF INPUT 18 Heater signal HEATER SIGNAL
22 ON/OFF INPUT 20 Shift lever signal "R" SHIFT LEVER "R"
23 ON/OFF INPUT 21 Shift lever signal "N" SHIFT LEVER "N"
24 ON/OFF INPUT 22 Shift lever signal "D" SHIFT LEVER "D"
25 ON/OFF INPUT 23 Shift lever signal "6" SHIFT LEVER "6"
30 ON/OFF INPUT 28 Shift lever signal "1" SHIFT LEVER "L"
34 ON/OFF INPUT 32 Machine select 1 MACHINE SELECT 1
HD465-7, HD605-7 10-143

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GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE

• The relationship between each gearshift position and the automatic gearshifting range is as shown in the
table below.
Gearshifting characteristics HD465-7 Serial No.: 7484 and up

• Shifting the transmission up and down is carried HD605-7 Serial No.: 7182 and up
out according to the shift map saved in the con- Mode Set conditions
troller memory.
There are three types of shift map, depending on Braking 1. Brake signal ON
mode (footbrake, retarder brake operated)
the condition of the input signals.
The settings for each mode are as shown in the When the following three conditions are
table below. fulfilled
High power 1. Brake signal OFF
mode (footbrake, retarder brake not operated)
HD465-7 Serial No.: 7001 – 7483 2. Accelerator pedal depressed
HD605-7 Serial No.: 7001 – 7181 3. Power mode selector switch is at high power
Mode Set conditions When the following two conditions are fulfilled
Economy 1. Brake signal OFF
When either of the following conditions is mode (footbrake, retarder brake not operated)
fulfilled 2. Power mode selector switch is at economy
Braking
1. Brake signal ON
mode
(footbrake, retarder brake operated)
2. Accelerator pedal released
Braking mode:
The shift-down point and the shift-up point are both
When the following three conditions are raised, the engine speed is maintained at a higher
fulfilled
High power 1. Brake signal OFF level, and the amount of cooling oil for the retarder is
mode (footbrake, retarder brake not operated) ensured to provide greater effect when the engine is
2. Accelerator pedal depressed used as a brake.
3. Power mode selector switch is at high power
When the following three conditions are High power mode:

fulfilled The high power mode uses the power of the
Economy 1. Brake signal OFF
mode (footbrake, retarder brake not operated) machine to the maximum to provide the maximum
2. Accelerator pedal depressed payload.
3. Power mode selector switch is at economy
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower
level, and the fuel consumption, noise, and trans-
mission shock are improved.
10-144 HD465-7, HD605-7

(12)
AUTOMATIC GEARSHIFTING GRAPH

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

(12)

• The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Lock-up
• For the lock-up ON point, the optimum point
between 1,300 and 1,500 rpm is selected
according to the torque converter input speed
(engine speed) and output speed (transmission
input shaft speed).
• When the machine moves off downhill F1, F2
with the accelerator pedal released, the lock-up
is not engaged until the accelerator pedal is
depressed or the footbrake is applied.
10-145-1 HD465-7, HD605-7

(12)
Gearshift lever positions and method of shifting 4) Gearshift lever position N

1) Gearshift lever position D At the neutral position, none of the transmission
When shifting up (in high power mode) clutches are actuated.
i) When the gearshift lever is set at position D,
the transmission is set to F2 torque converter
range. Gearshifting load time
ii) When the accelerator pedal is depressed, • In the automatic shift range, to prevent mistaken
the engine speed rises and accelerates. operation caused by excessive variation in the
When the transmission input shaft speed speed when shifting gear, a time delay is used to
reaches 1,300 – 1,500 rpm, the lock-up prevent the gears from being shifted within the
clutch is engaged, so the torque converter is set time.
directly engaged and the transmission is set The gearshifting time delay is controlled pre-
to direct travel. cisely by each gearshifting pattern through the
iii) As the engine speed rises further and use of the all-range electronic modulation sys-
reaches 2,100 rpm, the transmission shifts tem.
up to F3. The approximate values for the gearshifting pat-
While the transmission is shifting up, the tern and gearshifting time delay are shown in the
engine speed is also lowered (a command is diagram below.
output to the engine controller) in order to
reduce the shock when shifting gear.
iv) Immediately after shifting up, the engine
speed momentarily goes down, but as the
machine accelerates, it rises again and the
transmission shifts up in turn to F4 to F7 in
the same way as in iii) above.
When shifting down (in high power mode)

i) When the load increases and the engine
speed drops to 1,400 rpm, the transmission
shifts down one speed.
(For example, when traveling in F6, the
transmission shifts down to F5.)
While the transmission is shifting down, the
engine speed is also raised (a command is
output to the engine controller) in order to
reduce the shock when shifting gear.
ii) As the engine speed goes down further and
the transmission shifts down in turn to F2,
the torque converter lock-up clutch is disen-
gaged and the transmission enters the
torque converter drive.
• In the above explanation, the set speed or actua-

tion may differ according to the travel conditions.
For details, see the automatic gearshifting graph.
2) Gearshift lever positions 6, 5, 4, 3, 2, L

The method of shifting automatically from F1 to
F6 (F5, F4, F3, F2) is the same as for gearshift
lever position D above.
3) Gearshift lever positions R
This is the shift lever position for REVERSE
travel. So, the lockup does not work.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety. If
the operation is not correct, gearshifting is
restricted, and the engine speed is reduced at a
time.
10-146 HD465-7, HD605-7

(12)
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, FUNC-
TION, and MAINTENANCE STANDARD, "Initial
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

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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

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

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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
a Communication "transmitting" lamp (3)
lights up even when the communication
cable is not connected to a PC or when
there is defective connection.
a When not inserting or removing memory
card (9), always keep cover (10) closed.
10-154 HD465-7, HD605-7

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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
a The switches are adjusted before the machine is
shipped. Only No. 7 and No. B can be adjusted.
For this reason, do not touch any other switch.
HD465-7, HD605-7 10-155

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• 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 (permitted) Bottom (prohibited)
Top
Left (1) (2)
(memory card not used)
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

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Payload meter has the following basic functions.

i) Power ON (reset)
When the power is turned ON, all functions are checked and displayed.
a 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

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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
FLOATo Aggregate mass display

When dumping (*2) N RAISE o LOWER OFF
o 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)
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.
10-158 HD465-7, HD605-7

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

Maintenance Manual)
a) Cycle data
a The period between one dumping operation and
the next dumping operation is taken as one cycle
and the data are recorded.
a The cycle data are recorded when the dumping
conditions are fulfilled (see right).
a 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
Data processing on PC
Analog spare 2
Data inside cycle are handled
MAX electric potential V 0-4.0
separately as spare signal input data.
MIN electric potential V 0-4.0
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

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b) Engine ON/OFF data

a Each time the engine was stopped and started is recorded.
a 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

Month Month 1-12
Day Day 1-31 Shows when engine was switched ON
Time Hour Hour Displayed as 0-23
Time Minute Minute 0-59
Month Month 1-12
Day Day 1-31 Shows when engine was switched OFF
Aggregate load mass t (Metric ton) or 0-9999000 Total value between engine ON and engine
US ton (Short ton) OFF
Total number of cycles Times 0-9999
c) Abnormality, warning data

a Each time a payload meter abnormality or warning is generated or cancelled is recorded.
a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets
Item Unit Range
Engine operation number when According to 5

error code was generated Integer 0-65535
Frequency of generation Times 1-255
after engine is switched ON

Month Month 1-12
Shows when error code was generated
Day Day 1-31
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 cancelled
Day Day 1-31
Time Hour Hour (0 – 23) Displayed as 0-23
10-160 HD465-7, HD605-7

(10)
d) Data for aggregate load mass, total number of cycles

a It is possible to calculate and record again from any desired time the aggregate load mass and total
number of cycles for each time that the dumping conditions are fulfilled.
a The calculation is started again for both values when the data for aggregate load mass and total number
of cycles are cleared.
a 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

Month Month 1-12
Day Day 1-31 Shows date and time when data were cleared
e) 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
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

(10)
f) Calibration data
a These are saved in RAM each time calibration is performed.
a The maximum limit in memory for calibration data is 15 sets.
Item Unit Range
Year Year (last 2 digits) 00-99

Month Month 1-12
Day Day 1-31 Shows values and settings when cali-
Time Hour Hour 0-23 bration was performed
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
Suspension pressure (rear right) x 98 kPa 0-6553.5
Shows values before compensation fac-
Mass on spring (front) t (Metric ton) 0-6553.5
tor 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)
g) Load mass calculation data (analog data)

a These are saved in RAM when the load mass calculation data are required.
a 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 a) – g) are retained even when the power is switched OFF.
10-162 HD465-7, HD605-7

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

It is possible to adjust the brightness of the pay- This forcibly deletes all the calibration data
load meter II display portion to 10 levels with the and analog data, except for the latest calibra-
LIGHT/INC switch. tion data.
ix) Downloading saved data a Before clearing the data, always download
It is possible to download any data recorded in the data to a PC or carry out a) Card dump.
payload meter to a PC through a cable (ANSI/
E1A RS-232C). e) Input signal condition display
For details, see the PC software manual pro- This displays some of the signal conditions
vided by Komatsu. for the sensors input to payload meter and
the present recognition condition of the pay-
load meter.
f) Forced initialization
This forcibly deletes all the data in payload
meter .
a 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.
g) 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

(10)
h) 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
4 – 9 set The time that machine is Load mass last displayed in
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
i) 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)
j) 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 1
690 – 1,690 [ x 100
t]
HD605-7
HD785-5 1
1,000 – 2,000 [ x 100
t]
HD985-3
10-164 HD465-7, HD605-7

(10)
k) Zero ton display range setting

This is used to input and correct the values
to set the range of the zero display on the
load mass display.
Possible set range: 5 – 10
[%: ratio of correct load mass]
l) External display lamp display range setting

This is used to input and correct the values
to set the lamp display load mass range
when displaying the load mass.
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.
t 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, c) and d) 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.
f) is actuated only when the power is ON.
a 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

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

(6)
(a) Operation for calibration data display
1. Set to CHEC display, then press CAL/CLE

switch (1) for at least 2 seconds.
Display: CALO
2. Every time the CAL/CLE switch (1) is pressed, From CALO flashing Remarks
the display changes in the order shown on the Last 2 digits of year for date
1
right. when CAL was carried out
Month and day for date when
2
CAL was carried out
3. If MODE switch (2) is pressed at any time during
Hour and minute for date
the display in Steps 1. or 2., the display will 3
when CAL was carried out
return to CHEC. (End) 4
Model selection switch (decimal
value) when CAL was carried out
5 x 98kPa P'FL (Front left) Suspension
pressure less than
6 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
7 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
8 x 98kPa P'RR (Rear right)
t Mass on front axle Less than 100 t:
9 x 2 (P'FL+P'RL))
(= –
4
D F– XX.X
t Mass on rear axle More than 100 t:
10 x 2 XXX.X
(= –4 D R
– (P'RL+P'RR))
Appears when value is
Angle of tilt when CAL was negative
11 x
180 rad carried out O
(–) X.XX
12 Front axle tilt coefficient
13 Rear axle tilt coefficient

X.XXX
14 Front axle link coefficient
15 Rear axle link coefficient

Spring-up mass calculated Same number of digits as 9.
All
16displayed values are rounded to and 10.
according to calibration
the value given.
17 CALO flashes
Returns to 1. and
repeats sequence
HD465-7, HD605-7 10-167

(10)
(b) Operation for payload calculation data (analog data) display
1. Set to CHEC display, then press LIGHT/INC

switch (1) for at least 2 seconds.
Display: ALLO (when data in memory is
less than 170 cycles)
A.FUL (when data in memory is
more than 170 cycles)
A.FUL (when data in memory is
more than 180 cycles)
2. Every time the LIGHT/INC switch (1) is pressed, From ALLO flashing or A.FUL
Remarks
the display changes in the order shown on the flashing
right. 1 Hour, minute

2 x 98kPa P'FL (Front left) Suspension
pressure less than
3. If MODE switch (2) is pressed at any time dur- 3 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
ing the display in Steps 1. or 2., the display will 4 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
return to CHEC. (End) XXX.X
5 x 98kPa P'RR (Rear right)
t Mass on front axle Suspension
6 x 2 pressure less than
(= –
4
D–
F
(P'FL+P'RL))
100 x 98 kPa: XX.X
t Mass on rear axle More than 100 x 98 kPa:
7 x 2
(= –
4
D–
R
(P'RL+P'RR)) XXX.X
Appears when value is
Angle of tilt when CAL was negative
8 x 180 rad carried out O
(–) X.XX
9 Front axle tilt coefficient
10 Rear axle tilt coefficient X.XXX

11 Front axle link coefficient
12 Rear axle link coefficient
Spring-up mass calculated
13 t Same as 7. and 8.
according to calibration
14 — GT o Gain trimmer
15 t Present load mass Same as 7. and 8.
16 V Backup battery
X.X
Voltage
17 ALLO flashing
Returns to (1) and
repeats sequence
All displayed values are rounded to

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

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

(10)
(e) Operation for input signal condition display
(2-d) Battery charge signal condition

Display: C4:XX (lights up for 3 seconds)
Engine running: C4 : oo
Engine stopped: C4 : — —
O
(2-e) Analog spare input 1 signal condition
X.X .... Input signal (V)
O
(2-f) Analog spare input 2 signal condition
X.X .... Same as C5
O
1. Set to CHEC display, then press TOTAL/SFT (2-g) Digital spare input 1 signal condition
switch (1) and CAL/CLR switch (2) at the same Display: C7:XX (lights up for 3 seconds)
time for at least 2 seconds.
Display: S : CHE Hi:C7 : oo
Lo: C7 : — —
2. Every time CAL/CLR switch (1) is pressed, the O
display changes in the order shown below. (2-h) Digital spare input 2 signal condition
Display: C8 : XX (lights up for 3 seconds)
(2-a) Parking brake, brake lock switch signal condi- X.X .... Same as C7
tion [HD1200-1] O
Display: C1:XX (lights up for 3 seconds) (2-i) Travel speed display
Display: C9 : XX
Either one ON:CL : oo X.X .... Travel speed (km/h)
Both OFF:CL : — — O
O (2-j) Travel distance display
(2-a’) Shift lever position signal condition
[except HD1200-1] Travel distance with machine in present
Display: C1: XX (lights up for 3 seconds) condition (empty or loaded) for that cycle
"N":CL : oo XXXX .... (m)

Except "N":CL : — —
O * If the value goes above 9999m, the display
(2-b) Dump lever position signal condition starts again from 0.
Display: C2:XX (lights up for 3 seconds) O
Go to next page
F. FLOAT:C2 : oo
Except FLOAT:C2 : — —
O
(2-c) Engine oil pressure signal condition
Engine running:C3 : oo
Engine stopped:C3 : — —
O
10-170 HD465-7, HD605-7

(10)
( f ) Operation for performing forced initialization
From previous page

O
(2-k) Payload meter present recognition display
Counter display
Empty stopped ............. 03.01

Empty traveling............. 01.02
Loading......................... 06.03
Loaded traveling ........... 02.04
Loaded stopped............ 04.05
Dumping ....................... 05.06 1. Set to CHEC display, then press CAL/CLR
switche (11), TOTAL/SFT switch (2) and LIGHT/
Invariable May change INC switch (3) at the same time for at least 2
according to
N signal when seconds.
O dumping Display: :
(2-l) Machine condition time display shown below
Every time CAL/CLR switch (1) is pressed, the 2. Press CAL/CLR switch (1) for at least 2 seconds.
display advances one place in order from a) to The display becomes : (lighted up) (2
f). seconds),
and when all the data is completely cleared, it
a Empty traveling S1 : automatically displays F.CAL. (End)
b Empty stopped S2 : After that, it carries out the process from 10.3.
c Loaded traveling S3 :
If it is desired to stop the forced initialization
d Loaded stopped S4 :
operation when the display is : ,
e Dumping S5 :
press MODE switch (4), and the display will
f Loading S6 : return to CHEC without performing the forced ini-
tialization operation.
* The value for the

present machine
recognition con-
dition increases
in minutes in real
time.
3. If MODE switch (3) is pressed at any time during

the display in Steps 1. or 2., the display will
return to CHEC. (End)
HD465-7, HD605-7 10-171

(10)
(g) Operation for setting extra load mass when loading (h) Operation for setting load mass fixed display and
cycle data record value
1. Set to CHEC display, then press TOTAL/SFT

switch (1) and LIGHT/INC switch (2) at the same 1. Set to UP : XX display, then press CAL/CLR
time for at least 2 seconds. switch (4)
Display: S.5EL Display: PL : XX (present set value)
2. Press CAL/CLR switch (3). If it is necessary to correct the setting, press

LIGHT/INC switch (2) and correct.
Display UP : XX present set value:for + : X
for – : – X When the correction operation is completed,
If it is necessary to correct the setting, press press MODE switch (1) at any time to return to
LIGHT/INC switch (2) and correct. the CHEC display. (End)
3. When the correction operation from Step 1. is

completed, press MODE switch (4) at any time
to return to the CHEC display. (End)
10-172 HD465-7, HD605-7

(10)
( i) Operation for setting loading completion recogni- ( j ) Operation for setting loading start recognition
tion travel distance load mass
1. Set to PL : XX display, then press CAL/CLR 1. Set to O.SEL display, then press CAL/CLRswitch
switch (4) (4)
Display: O.SEL Display: P.SEL
2. Press TOTAL/SFT switch (3). 2. Press TOTAL/SFT switch (2).

Display: XXX Display: XXXX
If it is necessary to correct the setting If it is necessary to correct the setting
for the units, press LIGHT/INC switch for the tens, press LIGHT/INC switch
(2) and correct. (2) and correct.
3. Press CAL/CLR switch (4). 3. Press CAL/CLR switch (4).

Display: XXX Display: XXXX
If it is necessary to correct the setting If it is necessary to correct the setting
for the tens, press LIGHT/INC switch for the hundreds, press LIGHT/INC
switch (2) and correct.
(2) and correct.
4. Press CAL/CLR switch (4) again.
4. Press CAL/CLR switch (4) again. Display: XXXX
Display: XXX If it is necessary to correct the setting
If it is necessary to correct the setting for the thousands, press LIGHT/INC
for the hundreds, press LIGHT/INC
switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the dis-
play will return to Step 3, so it is possible to cor-
rect again.
5. If CAL/CLR switch (4) is pressed again, the dis-
play will return to XXX, so it is possible to correct 6. When the correction operation from Step 1. is
the units again. completed, press MODE switch (1) at any time to
return to the CHEC display. (End)
completed, pressMODE switch (1) at any time to If it is impossible to set the input values even
return to the CHEC display after displaying when MODE switch (1) is pressed, it returns to
O.XXX (input value). (End) Step 1.
If it is impossible to set the input values even
when MODE switch (1) is pressed, it displays
O.XXX (input value) and returns to Step 2..
HD465-7, HD605-7 10-173

(10)
(k) Operation for setting 0 ton display range
1. Set to P.SEL display, then press

CAL/CLR switch (4)
Display: H.SEL
2. Press TOTAL/SFT switch (3).

Display: – – XX (present value)
If it is necessary to correct the setting,
press LIGHT/INC switch (2) and cor-
rect.

completed, press MODE switch (1) at any time to
10-174 HD465-7, HD605-7

(10)
( l) Operation for setting display range of external

display lamps
Display: E.XXX
(present value of lamp 5)
If it is necessary to correct the display
range for lamp 5, press LIGHT/INC

completed, press MODE switch (1) at any time to
If it is impossible to set the input values even

when MODE switch (1) is pressed, it displays
d.FAL (input value) and returns to Step 2.
1. Set to H.SEL display, then press CAL/CLR
switch (4)
Display: E.SEL
2. Press TOTAL/SFT switch (3).

Display: A.XXX
3. Press CAL/CLR switch (4).

Display: b.XXX

Display: C.XXX

Display: d.XXX
HD465-7, HD605-7 10-175

(10)
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)
3. Clinometer
To carry out compensation on slopes, the clinom-
eter measures the tilt angle of the chassis in the
front-to-rear direction.
The output characteristics of the clinometer are

as shown in the diagram on the right.
 Voltage between clinometer connector pin 1 
 (GND) and pin 2 (output) or voltage of out- 
 put (pin (8)) of clinometer when pin (3) of 
 payload meter controller connector (PH6 
 pin) is grounded 
4. Lamp drive relay

The external display lamps are driven by a signal
from the payload meter.
HD465-7, HD605-7 10-179

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 payload,
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 kg/cm2
pressure sensor system or 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
10-180 HD465-7, HD605-7

Saving abnormality,
warning data (PC soft- Remarks
ware display code)
— Display timing for other
than HD1200-1: Shift
lever position N
— Display timing for other

than HD1200-1: Shift
lever position other than
N
— Detected only when
performing card dump
Records Rated voltage: 3.6 V

(000-009)
Records
(000-011)
(000-012)
(000-013)
(000-014)
Records —
(000-018)
Records Calibration cannot be

(000-020) performed when there is
abnormality

abnormality
(000-022)
(000-023)
(000-024)
HD465-7, HD605-7 10-181

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 19.6 MPa
sure sensor system {200 kg/cm2} or
12 Short circuit with more
F-26 flashes
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 +100 removed
in clinometer system
16 Short circuit with power Clinometer input F-32 flashes
source in clinometer signal above –
system 100 EG
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

Saving abnormality,
warning data (PC soft- Remarks
ware display code)
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 Payload 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

AUTOMATIC EMERGENCY
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING SYSTEM
AUTOMATIC EMERGENCY STEERING SYSTEM

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

(12)
AUTOMATIC EMERGENCY
FLOW SWITCH
1. Wire cable Outline

2. Housing The flow switch is a switch for the auto emergency
3. Magnet steering and is installed in the piping of the steering
4. Pivot pin hydraulic circuit. If the flow of oil inside the hydraulic
5. Disc piping drops below the specified level or stops, the
6. Spring flow switch detects this and actuates the lead switch.
7. Lead switch
HD465-7, HD605-7 10-185

AUTOMATIC EMERGENCY
Operation
• When oil flow is above specified level
Plate (5) is pushed in the direction of the oil flow
a by the oil in the piping. When this pushing
force overcomes spring (6), magnet (3) is moved
to the right (pivot pin (4) is taken as the center of
rotation).
When this happens, the contact with the lead
switch is opened and the circuit is switched OFF.
• When oil flow is below specified level or

stops.
The force of the oil in the piping pushing plate (5)
is weaker than spring (6), so magnet (3) returns
to the left.
switch is closed and the circuit is switched ON.
10-186 HD465-7, HD605-7

AUTOMATIC EMERGENCY
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 or 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

(9)
AUTOMATIC EMERGENCY

1. Timer Outline
2. Batter If the engine should stop when the machie is travel-
3. Steering oil pressure switch ing, or there is any abnormality in the hydraulic pump
4. Emergency steering motor and the specified amount of oil does not flow to the
5. Emergency steering pump steering circuit, the emergency system automatically
6. Demand valve actuates an electric pump to ensure the hydraulic
pressure for the steering, thereby making it possible
to use the steering.
This system can also be operated manually.
10-187-1 HD465-7, HD605-7

(12)
AUTOMATIC EMERGENCY
FLOW SWITCH
1. Wire cable Outline

2. Housing The flow switch is a switch for the auto emergency
3. Magnet steering and is installed in the piping of the steering
4. Pivot pin hydraulic circuit. If the flow of oil inside the hydraulic
5. Disc piping drops below the specified level or stops, the
6. Spring flow switch detects this and actuates the lead switch.
7. Lead switch
HD465-7, HD605-7 10-187-2

(12)
AUTOMATIC EMERGENCY
Operation
• When oil flow is above specified level
Plate (5) is pushed in the direction of the oil flow
a by the oil in the piping. When this pushing
force overcomes spring (6), magnet (3) is moved
to the right (pivot pin (4) is taken as the center of
rotation).
switch is opened and the circuit is switched OFF.
• When oil flow is below specified level or

stops.
The force of the oil in the piping pushing plate (5)
is weaker than spring (6), so magnet (3) returns
to the left.
switch is closed and the circuit is switched ON.
10-187-3 HD465-7, HD605-7

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

(12)
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 HD605 by
modes (damping force) are as shown in the table the switch for the transmission control system.
below.
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

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

(10)
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 (ARSC)

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 (if equipped)
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

(10)
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)
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 VALIDATION SW 1
7 D_IN_5 Lever validation 2 switch Pull up (5mA) LEVER VALIDATION 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

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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
A: To improve the initial response of the electro-

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

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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. 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" o Reverse
travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" o
Reverse travel not permitted
6. Calibration function
To absorb any inherent error in the dump body
potentiometer, 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) Lower the body to the seat, and then keep
the lever at the FLOAT position for at least 5
seconds.
4) Run the engine at low idling and operate
RAISE o FLOAT with the dump body raised
to the maximum height, then lower the dump
body completely. Repeat this operation 10
times.
5) Run the engine at high idling and operate
RAISE o 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

(6)
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

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

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TRANSMISSION OIL FILTER CLOGGING 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: 275 kPa {2.8 kg/cm2}
Principle of switch: Pressure difference sliding piston

type
STEERING OIL PRESSURE SWITCH (FOR AUTOMATIC EMERGENCY STEERING SYSTEM)
1. Piston Function
2. Body • The steering pressure switch is installed to the
3. Switch steering and hoist piping. If the oil pressure in
4. Connector the steering circuit lowers below the set level
while the engine is running, the steering pres-
sure switch starts the electric pump to secure the
oil pressure for steering.
HD465-7, HD605-7 10-207

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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

(6)
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 LEVER
DUMP LEVER
10-212 HD465-7, HD605-7

(10)
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

(10)
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 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

(10)
2. Dump lever FLOAT canceled 4. Dump 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 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 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

(10)
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.
Specifications
1. Voltage of power supply : DC20V - DC30V
2. Size (mm) : W272 x D169 x H72
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)
or more
3. Size: Mount (portion a) : R 1/4
: Outside diameter of
seat receiving pres-
sure : 37 mm
: 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

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE OIL TEMPERATURE SENSOR
ENGINE OIL TEMPERATURE

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) (kz) (°C) (kz) (°C) (kz)
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

(10)
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

(kz)
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

(10)
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 calculated
as above on the monitor screen and displays the
load level on the outside indicator 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 "Replacing Parts".
HD465-7, HD605-7 10-221

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ELECTRIC CIRCUIT DIAGRAM

See TROUBLESHOOTING, Troubleshooting of
VHMS controller system (VHMS mode).
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.
a Travel signal sensor:
Transmission output shaft speed sensor
10-222 HD465-7, HD605-7

(10)
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, Setting up VHMS controller.
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

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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 and Maintenance 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 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

(10)
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 (EMMS)".
HD465-7, HD605-7 10-225

(10)
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. 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

(10)
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

(10)
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)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

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

(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

HD465-7 Serial No.: 7001 – 7483
Model
HD605-7 Serial No.: 7001 – 7181
Engine SAA6D170E-3
Permissible
Item Measurement conditions Unit Standard value value
Power mode 2,270 ± 50 2,270 ± 50
High idle Economy mode 2,200 ± 50 2,200 ± 50
Stationary mode +0 +0
(*1) 2,100 – 100 2,100 – 100
Engine Speed Hi rpm 945 ± 50 945 ± 50

Low idle
Lo 750 ± 50 750 ± 50
Power mode 2,000 ± 50 2,000 ± 50

Rated speed
Economy mode 1,900 ± 50 1,900 ± 50
• Hi power mode kPa Min. 106.6 Min. 93.3

Boost pressure • Torque convertor stall {mmHg} {Min. 800} {Min. 700}
# 1, 2, 3 Max. 670 Max. 700

• Hi power mode
Exhaust temperature • Torque convertor stall °C
# 4, 5, 6 Max. 670 Max. 700
At sudden acceleration Max. 3.5 Max. 6.0

Bosch
Exhaust gas color index
At high idle Max. 1.0 Max. 2.5
Intake valve 0.32 —

Valve clearance
(Normal temperature) mm
Exhaust valve 0.62 —
Compression pressure Oil temperature: 40 – 60°C MPa

(SAE30 oil) (Engine speed: 210 – 250 rpm) {kg/cm2} Min. 2.9 {30} Min. 1.96 {20}
(Coolant temperature: Operating range)

Blow-by pressure • Power mode kPa Max. 5.4 {550} Max. 8.8 {900}
• Torque convertor stall {mmH2O}

At high idle (SAE30) 0.392 – 0.539 Min. 0.206 {2.1}
{4.0 – 5.5}
At high idle (SAE10W) MPa 0.343 – 0.539 Min. 0.177 {1.8}
Oil pressure {kg/cm2} {3.5 – 5.5}
At low idle (SAE30) Min. 0.118 {1.2} Min. 0.080 {0.8}
At low idle (SAE10W) Min. 0.098 {1.0} Min. 0.069 {0.7}

Whole speed range
Oil temperature (Inside oil pan) °C 90 – 110 120
Deflection when pressed with finger

Belt tension (Alternator) force of approx. 58.8 N {6 kg} mm 15 15
*1) Condition for stationary mode:

Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT"
position.
When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" posi-
tion.
20-2 HD465-7, HD605-7

(12)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

HD465-7 Serial No.: 7001 – 7483
HD605-7 Serial No.: 7001 – 7181
Com- Item Measurement conditions Unit Standard Permissible
ponent value value
• Engine coolant temperature: Standard tires Standard tires
Within operating range
F1 • Transmission oil temperature: 11.5 ± 5 % 11.5 ± 5 %
60 – 80°C
F2 • Machine unloaded 16.0 ± 5 % 16.0 ± 5 %
• Travel resistance: 3.3 %
Performance
F3 21.5 ± 5 % 21.5 ± 5 %
Travel speed F4 km/h 29.5 ± 5 % 29.5 ± 5 %
F5 39.0 ± 5 % 39.0 ± 5 %
F6 52.5 ± 5 % 52.5 ± 5 %
F7 70.0 ± 5 % 70.0 ± 5 %
R 12.0 ± 5 % 12.0 ± 5 %
Shift up • Engine coolant temperature: 2,100 ± 50 2,100 ± 50

High power • Transmission oil temperature: 1,400 ± 50 1,400 ± 50
mode 60 – 80°C
Shift down
Automatic shift control
• Hydraulic oil temperature: 1,325 ± 35 1,325 ± 35

45 – 55°C (F2 o F1 only) (F2 o F1 only)
• “Braking mode” refers to when the
Shift up 2,000 ± 50 2,000 ± 50
accelerator is OFF or the rear
Economy brake is ON. 1,300 ± 50 1,300 ± 50
mode
Shift down
1,250 ± 50 1,250 ± 50
(F2 o F1 only) (F2 o F1 only)
Shift up 2,450 ± 50 2,450 ± 50
Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
Auto lock-up
Set *1 *1
Engine speed
Reset rpm *2 *2
Overrun prevention
Set 2,600 ± 10 2,600 ± 10
Reset 2,350 ± 10 2,350 ± 10
Down-shift inhibitor 1,325 ± 35 1,325 ± 35

• Transmission oil temperature:
Power
mode
85 – 110°C 1,910±100 1,910 ± 100

• Hydraulic oil temperature:
converter
Torque
Engine speed at torque 45 – 55°C

converter stall • Engine coolant temperature:
Economy
mode

1,910±100 1,910 ± 100
*1. Torque converter speed ratio is min. 0.85 at min. 1,500 rpm or min. 1,300 rpm
*2. F3 – F7: 1,050 ± 50
F1, F2 : 1,100 ± 50
HD465-7, HD605-7 20-3

(12)

ponent value value
Starting to • Operating effort at a point 150 22.5 ± 4.9 22.5 ± 4.9
Accelerator pedal
depress mm from pedal fulcrum {2.3 ± 0.5} {2.3 ± 0.5}

Operating N
force {kg} 42.1 +– 7.8
2.0
42.1 –+ 7.8
2.0
Fully + 0.3 + 0.3
{4.3 – 0.8
} {4.3 – 0.8
}
Starting to • Travel at a point 150 mm from

Travel depress i o pedal fulcrum mm 45 ± 5 45 ± 5
fully
• At center of lever knob N 21.6 ± 3.9 Max. 29.4{3}
Operating force {kg} {2.2 ± 0.4}
Transmission shift lever
R–N
N–D
D–5
Travel mm 24.5 ± 1 24.5 ± 2
5–4
4–3
3–L
0.74 ± 0.05 0.74 ± 0.05
At engine speed 2,000 rpm {7.5 ± 0.5} {7.5 ± 0.5}
Inlet oil At high idle (2,270 rpm) 0.88 ± 0.05 0.88 ± 0.05
pressure (Reference value) {8.9 ± 0.5} {8.9 ± 0.5}
At low idle (750 rpm) 0.17 ± 0.05 0.17 ± 0.05
(Reference value) {1.7 ± 0.5} {1.7 ± 0.5}
0.59 ± 0.05 0.59 ± 0.05
Outlet oil At high idle (2,270 rpm) 0.71 ± 0.05 0.71 ± 0.05
Torque converter
At low idle (750 rpm) 0.15 ± 0.05 0.15 ± 0.05

• Oil temperature: (Reference value) MPa {1.5 ± 0.5} {1.5 ± 0.5}
75 – 85°C {kg/cm2} 1.67 ± 0.20 1.67 ± 0.20
At engine speed 2,000 rpm {17 ± 2} {17 ± 2}
Lock-up oil At high idle (2,270 rpm) 1.67 ± 0.20 1.67 ± 0.20
pressure (Reference value) {17 ± 2} {17 ± 2}
At low idle (750 rpm) 1.67 ± 0.20 1.67 ± 0.20
(Reference value) {17 ± 2} {17 ± 2}
3.68 ± 0.15 3.68 ± 0.15
Main relief At high idle (2,270 rpm) 3.77 ± 0.15 3.77 ± 0.15
oil pressure (Reference value) {38.5 ± 1.5} {38.5 ± 1.5}
At low idle (750 rpm) 3.33 ± 0.15 3.33 ± 0.15
(Reference value) {34 ± 1.5} {34 ± 1.5}
• Oil temperature: 60 – 80°C 1.67 ± 0.2 1.67 ± 0.2
H, 4th clutch {17 ± 2} {17 ± 2}
• Engine: at rated speed
1.82 ± 0.2 1.82 ± 0.2
L clutch
Transmission
{18.5 ± 2} {18.5 ± 2}
Control MPa 1.77 ± 0.2 1.77 ± 0.2
valve set 3rd clutch {kg/cm2} {18 ± 2} {18 ± 2}
pressure
3.33 ± 0.2 3.33 ± 0.2
2nd clutch {34 ± 2} {34 ± 2}
3.58 ± 0.2 3.58 ± 0.2
1st clutch {36.5 ± 2} {36.5 ± 2}
20-4 HD465-7, HD605-7

(10)

ponent value value
• Oil temperature: 0.15 ± 0.05 0.15 ± 0.05
60 – 80°C At engine speed 2,000 rpm
{1.5 ± 0.5} {1.5 ± 0.5}
Transmission
(When using
EO10-CD)
Lubricating or At high idle (2,270 rpm) MPa 0.17 ± 0.05 0.17 ± 0.05
oil pressure Oil temperature: (Reference value) {kg/cm2} {1.7 ± 0.5} {1.7 ± 0.5}
80 – 100°C
(When using At low idle (750 rpm) 0.09 ± 0.05 0.09 ± 0.05
EO30-CD) (Reference value) {0.9 ± 0.5} {0.9 ± 0.5}
• Machine unloaded
(Inflation pressure)
Standard 24.00-35-36PR 0.46 0.46

(Front and
tires rear tires) {4.75} {4.75}
Tires
MPa
{kg/cm2}
Tire 24.00-R35 0.69 0.69
(Front and
(If equipped) rear tires) {7.0} {7.0}
Braking capacity • With 46ton payload % Min. 25 Min. 25

Parking brake
• F2
Starting test rpm Min. 1,540 Min. 1,540
• Torque converter stall
Releasing pressure See Brake MPa See Brake

{kg/cm2}
• On flat road surface 249 ± 10 249 ± 20
Front A • When empty
Installed 249 ± 10 (*1) 249 ± 20 (*1)
Suspension cylinder
length mm
220 ± 10 220 ± 20
Rear B
204 ± 10 (*1) 204 ± 20 (*1)
Front 3.82 ± 0.39 3.82 ± 0.39

{39 ± 4} {39 ± 4}
MPa
Pressure {kg/cm2}
Rear 2.26 ± 0.29 2.26 ± 0.29
{23 ± 3} {23 ± 3}
• Oil temperature: 60 – 80°C

Operating force • When machine stopped (empty)
(Turning speed for steering N 14.7 – 29.4 Max. 35.3
(If it is impossible when the {kg} {1.5 – 3.0} {Max. 3.6}
wheel: 30 rpm) machine stopped, travel at low
speed with engine at low idle)
Steering wheel
• Length at circumference of steer-

ing wheel
Play mm Max. 135 Max. 135
• Engine stopped, until tires start to
move
No. of turns • Lock o lock Turns 3.5 ± 0.3 3.5 ± 0.6
Left o right • Oil temperature: 60 – 80°C Max. 4 Max. 5

Turning • Engine speed: Whole range sec.
time • Lock o lock
Right o left Max. 4 Max. 5
• Oil tem- 20.2 – 21.1 20.1 – 23.5
Steering
At high idle (2,270 rpm) {206 – 215} {205 – 240}

valve
Relief pres- perature: MPa

sure 45 – 55°C At low idle (750 rpm) {kg/cm2} 20.2 – 21.1 20.1 – 23.5
(Reference value) {206 – 215} {205 – 240}
*1. Cylinder with buffer ring
HD465-7, HD605-7 20-5

(10)

ponent value value
• Measure at position a (Position at
150 mm from fulcrum of pedal)
Operating force (Full) N 233 ± 29.4 234 ± 29.4

{kg} {23.8 ± 3} {23.8 ± 3}
Brake pedal
Travel (Start of depressing

o Full) mm 40 ± 5 40 ± 10
• At point 10 mm from tip of lever N 5.9 – 9.8 3.0 – 14.7

Retarder
Operating force
control
{kg} {0.6 – 1.0} {0.3 – 1.5}

lever
0 0
Travel deg 0 – 78 –2
0 – 78 –4

Emergency brake pedal

{kg} {30.2 ± 3} {30.2 ± 3}
• Initial speed: 32 km/h

46 ton • Distance from starting to lose
payload Max. 22.3 Max. 22.3
Service speed to stopping
brake m
braking • Max. hydraulic pressure
distance Rear: 9.8 MPa {100 kg/cm2}
Empty Front: 17.6 MPa {180 kg/cm2} Max. 17.0 Max. 17.0
• On flat, dry road surface
Front • Engine: Stopped 17.6 ± 1.2 17.6 ± 1.2

• When first operated {180 ± 12} {180 ± 12}
Brake
actuating Rear 9.8 ± 0.7 9.8 ± 0.7
pressure (service) {100 ± 7} {100 ± 7}
MPa
Rear {kg/cm2} 8.7 ± 0.6 8.7 ± 0.6
Brakes
(retarder) {88.5 ± 6.5} {88.5 ± 6.5}

• Engine: Stopped 9.85 +– 0.49
0.98 9.85 –+ 0.49
0.98
Parking brake releasing
pressure {100.4 +– 510 } {100.4 +– 510 }
• Carrying 46 ton payload

Stopping distance when • Initial speed: 32 km/h m Max. 52.1 Max. 52.1
emergency brake is applied
Operating pressure 17.6 ± 1.2 17.6 ± 1.2

at first operation after Front {180 ± 12} {180 ± 12}
accumulator is
charged MPa 9.8 ± 0.7 9.8 ± 0.7
Brake oil pressure Rear {kg/cm2} {100 ± 7} {100 ± 7}
8.7 ± 0.6 8.7 ± 0.6
Retarder {88.5 ± 6.5} {88.5 ± 6.5}
20-6 HD465-7, HD605-7

(10)

ponent value value
Service brake Apply the brake and set the gear shift Must not move at 1,870 rpm
lever in D and raise the engine speed
Retarder brake gradually. Measure the engine speed Must not move at 1,400 rpm
when the truck starts moving rpm
Parking brake Must not move at 1,670 rpm
Must not move until torque
Emergency brake
Brakes
converter stall speed
Front brake Left side 19.5 3.0

mm
(Pad thickness ) Right side 19.5 3.0
Rear brake Left side Must be in wear gauge range

(Disc wear gauge ) —
Right side Must be in wear gauge range
• Engine: stopped HOLD Max. 29.4 Max. 35.3
• Center of control o RAISE {Max. 3.0} {Max. 3.6}
lever knob RAISE Must return smoothly when
o HOLD engine is running at high idle
HOLD Max. 29.4 Max. 35.3
o FLOAT N {Max. 3.0} {Max. 3.6}
Operating force {kg}
Dump lever
FLOAT Max. 29.4 Max. 35.3

o HOLD {Max. 3.0} {Max. 3.6}
o LOWER {Max. 3.0} {Max. 3.6}
LOWER Must return smoothly when
o FLOAT engine is running at 2,000 rpm
• Engine: stopped RAISE
o HOLD 44.8 ± 1.9 44.8 ± 1.9
• Center of control
Travel mm
lever knob HOLD
o LOWER 44.8 ± 1.9 44.8 ± 1.9
• Oil temperature: 20.1 – 21.1 19.6 – 22.6

Dump valve
45 – 55°C At high idle (2,270 rpm) {205 – 215} {200 – 230}

Relief pres-
sure
At low idle (750 rpm) 18.6 – 19.6 18.6 – 19.6
(Reference value) {190 – 200} {190 – 200}
MPa
Dump EPC valve
{kg/cm2} 3.4 ± 0.49 3.4 ± 0.49

At high idle (2,270 rpm) {35 ± 5} {35 ± 5}
Relief pres-
sure ( root
pressure)
At low idle (750 rpm) 2.6 ± 0.49 2.6 ± 0.49
Lifting speed • Oil temperature: 45 – 55°C 11.5 ± 1.5 11.5 ± 1.5

• Engine speed: 2,000 rpm sec.
Lowering speed • Use FLOAT when lowering 10.5 ± 1.5 10.5 +– 1.0
2.0
Body

• Set with No. 2 cylinder extended
Hydraulic drift mm Max. 85 170
200 mm
• Hydraulic drift after 5 minutes
HD465-7, HD605-7 20-7

(11)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Model
Engine SAA6D170E-3
Permissible
Item Measurement conditions Unit Standard value value
Power mode 2,270 ± 50 2,270 ± 50
+0
2,100 – 50
(empty)
High idle Economy mode 2,200 ± 50
2,270 ± 50 (loaded)
Stationary mode 2,100 +0
2,100 +0
(*1) – 50 – 100
Engine Speed rpm
Hi 945 ± 50 945 ± 50
Low idle
Lo 750 ± 50 750 ± 50
Power mode 2,000 ± 50 2,000 ± 50

Rated speed
Economy mode 1,900 ± 50 (empty) 1,900 ± 50
2,100 ± 50 (loaded)
• Hi power mode kPa Min. 106.6 Min. 93.3
Boost pressure • Torque convertor stall {mmHg} {Min. 800} {Min. 700}
# 1, 2, 3 Max. 670 Max. 700

• Hi power mode
Exhaust temperature • Torque convertor stall °C
# 4, 5, 6 Max. 670 Max. 700
At sudden acceleration Max. 3.5 Max. 6.0

Exhaust gas color Bosch
index
At high idle Max. 1.0 Max. 2.5
Intake valve 0.32 —

Valve clearance mm
(Normal temperature)
Exhaust valve 0.62 —
Compression pressure Oil temperature: 40 – 60°C MPa Min. 2.9 {30} Min. 1.96 {20}
(SAE30 oil) (Engine speed: 210 – 250 rpm) {kg/cm2}
(Coolant temperature: Operating range) kPa
Blow-by pressure • Power mode {mmH2O} Max. 5.4 {550} Max. 8.8 {900}
• Torque convertor stall
At high idle (SAE30) 0.392 – 0.539 Min. 0.206 {2.1}
{4.0 – 5.5}
At high idle (SAE10W) MPa 0.343 – 0.539 Min. 0.177 {1.8}
Oil pressure {kg/cm2} {3.5 – 5.5}
At low idle (SAE30) Min. 0.118 {1.2} Min. 0.080 {0.8}
At low idle (SAE10W) Min. 0.098 {1.0} Min. 0.069 {0.7}
Oil temperature Whole speed range °C 90 – 110 120

(Inside oil pan)
Belt tension (Alternator) Deflection when pressed with finger mm 15 15

force of approx. 58.8 N {6 kg}
*1) Condition for stationary mode:
Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT"
position.
When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" posi-
tion.
20-8 HD465-7, HD605-7

(12)
STANDARD VALUE TABLE FOR CHASSIS

ponent value value
F1 • Engine coolant temperature: 11.5 ± 5 % 11.5 ± 5 %

• Transmission oil temperature:
F2 60 – 80°C 16.0 ± 5 % 16.0 ± 5 %
F3 • Travel resistance: 3.3 % 21.5 ± 5 % 21.5 ± 5 %
• Standard tires
Performance
F4 • High power mode 29.5 ± 5 % 29.5 ± 5 %

Travel
speed km/h
F5 39.0 ± 5 % 39.0 ± 5 %
F6 52.5 ± 5 % 52.5 ± 5 %
F7 70.0 ± 5 % 70.0 ± 5 %
R 12.0 ± 5 % 12.0 ± 5 %
Shift up • Engine coolant tempera- 2,100 ± 50 2,100 ± 50

High ture:
power Within operating range 1,400 ± 50 1,400 ± 50
mode Shift down • Transmission oil tempera- 1,325 ± 35 1,325 ± 35
ture: 60 – 80°C (F2 o F1 only) (F2 o F1 only)
1,800/1,935 ± 50 1,800/1,935 ± 50
45 – 55°C
Full throttle
2,000 ± 50 2,000 ± 50
1,750 ± 50 1,750 ± 50
Empty
Half throttle 2,000 ± 50 2,000 ± 50


Engine speed
1,800 ± 50 1,800 ± 50
Accelerator rpm
OFF 2,450 ± 50 2,450 ± 50
Econ- (Slow travel)
omy Shift up
mode 1,935/2,070 ± 50 1,935/2,070 ± 50
Full throttle
2,100 ± 50 2,100 ± 50
1,750 ± 50 1,750 ± 50
Loaded
Half throttle 2,100 ± 50 2,100 ± 50

1,800 ± 50 1,800 ± 50
Accelerator
OFF 2,450 ± 50 2,450 ± 50
(Slow travel)
HD465-7, HD605-7 20-9

(12)

ponent value value
• Engine coolant tempera- 1,300 ± 35 1,300 ± 35
ture:
Full throttle
Within operating range 1,250 ± 35 1,250 ± 35
• Transmission oil tempera- (F2 o F1 only) (F2 o F1 only)
ture: 60 – 80°C
• Hydraulic oil temperature: 1,200 ± 35 1,200 ± 35
Half throttle 45 – 55°C
Empty
1,250 ± 35 1,250 ± 35
(F3oF2,F2oF1) (F3oF2,F2oF1)
1,200 ± 35 1,200 ± 35
Accelerator 1,250 ± 35 1,250 ± 35
OFF (F3 o F2 only) (F3 o F2 only)
(Slow travel)
1,550 ± 35 1,550 ± 35
Econ-
omy Shift 1,350 ± 35 1,350 ± 35
mode down
Full throttle
1,325 ± 35 1,325 ± 35
1,200 ± 35 1,200 ± 35
1,250 ± 35 1,250 ± 35
Half throttle
Loaded

1,325 ± 35 1,325 ± 35
Engine speed
1,200 ± 35 1,200 ± 35
Accelerator rpm
OFF 1,250 ± 35 1,250 ± 35
(Slow travel) (F3 o F2 only) (F3 o F2 only)
1,550 ± 35 1,550 ± 35
Shift up 2,450 ± 50 2,450 ± 50

Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
Torque converter Torque converter

speed ratio is speed ratio is
Set minimum 0.85 at minimum 0.85 at
Auto lock-up
minimum of 1,500 minimum of 1,500

rpm or 1,300 rpm. rpm or 1,300 rpm.
F3 – F7: F3 – F7:
1,050 ± 50 1,050 ± 50
Reset
F1, F2: F1, F2:
1,100 ± 50 1,100 ± 50
prevention
Set 2,600 ± 10 2,600 ± 10

Overrun
Reset 2,350 ± 10 2,350 ± 10
• Transmission oil tempera-

Power mode 1,910 ± 10 1,910 ± 10
Engine ture: 85 – 110°C
speed at
converter

Torque
torque Empty 1,800 ± 100 1,800 ± 100

con- 45 – 55°C
Econ- • Engine coolant tempera-
verter omy
stall mode ture:
Loaded Within operating range 1,875 ± 100 1,875 ± 100
20-10 HD465-7, HD605-7

(12)

ponent value value
Starting to • Operating effort at a point 150 22.5 ± 4.9 22.5 ± 4.9
depress {2.3 ± 0.5} {2.3 ± 0.5}
Accelerator pedal
mm from pedal fulcrum

Operating N
force {kg} 42.1 +– 7.8
2.0 42.1 –+ 7.8
2.0
Fully + 0.3 + 0.3
{4.3 – 0.8
} {4.3 – 0.8
}
Starting to • Travel at a point 150 mm from

Travel depress i o pedal fulcrum mm 45 ± 5 45 ± 5
fully
• At center of lever knob N 21.6 ± 3.9 Max. 29.4{3}
Operating force {kg} {2.2 ± 0.4}
Transmission shift lever
R–N
N–D
D–5
Travel mm 24.5 ± 1 24.5 ± 2
5–4
4–3
3–L
0.74 ± 0.05 0.74 ± 0.05
Inlet oil At high idle (2,270 rpm) 0.88 ± 0.05 0.88 ± 0.05
At low idle (750 rpm) 0.17 ± 0.05 0.17 ± 0.05
(Reference value) {1.7 ± 0.5} {1.7 ± 0.5}
0.59 ± 0.05 0.59 ± 0.05
Outlet oil At high idle (2,270 rpm) 0.71 ± 0.05 0.71 ± 0.05
Torque converter
At low idle (750 rpm) 0.15 ± 0.05 0.15 ± 0.05

• Oil temperature: (Reference value) MPa {1.5 ± 0.5} {1.5 ± 0.5}
75 – 85°C {kg/cm2} 1.67 ± 0.20 1.67 ± 0.20
At engine speed 2,000 rpm {17 ± 2} {17 ± 2}
Lock-up oil At high idle (2,270 rpm) 1.67 ± 0.20 1.67 ± 0.20
pressure (Reference value) {17 ± 2} {17 ± 2}
At low idle (750 rpm) 1.67 ± 0.20 1.67 ± 0.20
3.68 ± 0.15 3.68 ± 0.15
Main relief At high idle (2,270 rpm) 3.77 ± 0.15 3.77 ± 0.15
oil pressure (Reference value) {38.5 ± 1.5} {38.5 ± 1.5}
At low idle (750 rpm) 3.33 ± 0.15 3.33 ± 0.15
(Reference value) {34 ± 1.5} {34 ± 1.5}
• Oil temperature: 60 – 80°C 1.67 ± 0.2 1.67 ± 0.2
H, 4th clutch {17 ± 2} {17 ± 2}
• Engine: at rated speed
1.82 ± 0.2 1.82 ± 0.2
L clutch
Transmission
{18.5 ± 2} {18.5 ± 2}
Control MPa 1.77 ± 0.2 1.77 ± 0.2
valve set 3rd clutch {kg/cm2} {18 ± 2} {18 ± 2}
pressure
3.33 ± 0.2 3.33 ± 0.2
2nd clutch {34 ± 2} {34 ± 2}
3.58 ± 0.2 3.58 ± 0.2
1st clutch {36.5 ± 2} {36.5 ± 2}
HD465-7, HD605-7 20-11

(12)

ponent value value
• Oil temperature: 0.15 ± 0.05 0.15 ± 0.05
60 – 80°C At engine speed 2,000 rpm
{1.5 ± 0.5} {1.5 ± 0.5}
Transmission
(When using
EO10-CD)
Lubricating or At high idle (2,270 rpm) MPa 0.17 ± 0.05 0.17 ± 0.05
oil pressure Oil temperature: (Reference value) {kg/cm2} {1.7 ± 0.5} {1.7 ± 0.5}
80 – 100°C
(When using At low idle (750 rpm) 0.09 ± 0.05 0.09 ± 0.05
EO30-CD) (Reference value) {0.9 ± 0.5} {0.9 ± 0.5}
(Inflation pressure)
Standard 24.00-35-36PR 0.46 0.46

(Front and
tires rear tires) {4.75} {4.75}
Tires
MPa
{kg/cm2}
Tire 24.00-R35 0.69 0.69
(Front and
(If equipped) rear tires) {7.0} {7.0}
Braking capacity • With 46ton payload % Min. 25 Min. 25

Parking brake
• F2
Starting test rpm Min. 1,540 Min. 1,540
• Torque converter stall
Releasing pressure See Brake MPa See Brake

{kg/cm2}
• On flat road surface 249 ± 10 249 ± 20
Front A • When empty
Installed 249 ± 10 (*1) 249 ± 20 (*1)
mm
Suspension cylinder
length 220 ± 10 220 ± 20

Rear B
204 ± 10 (*1) 204 ± 20 (*1)
Front 3.82 ± 0.39 3.82 ± 0.39

{39 ± 4} {39 ± 4}
MPa
Pressure {kg/cm2}
Rear 2.26 ± 0.29 2.26 ± 0.29
{23 ± 3} {23 ± 3}

Operating force • When machine stopped (empty)
(Turning speed for steering N 14.7 – 29.4 Max. 35.3
(If it is impossible when the {kg} {1.5 – 3.0} {Max. 3.6}
wheel: 30 rpm) machine stopped, travel at low
speed with engine at low idle)
Steering wheel
• Length at circumference of steer-

ing wheel
Play mm Max. 135 Max. 135
• Engine stopped, until tires start to
move
No. of turns • Lock o lock Turns 3.5 ± 0.3 3.5 ± 0.6
Left o right • Oil temperature: 60 – 80°C Max. 4 Max. 5

Turning • Engine speed: Whole range sec.
time • Lock o lock
Right o left Max. 4 Max. 5
• Oil tem- 20.2 – 21.1 20.1 – 23.5
At high idle (2,270 rpm)
Steering
perature: {206 – 215} {205 – 240}

valve
Relief pres- MPa

sure 45 – 55°C At low idle (750 rpm) {kg/cm2} 20.2 – 21.1 20.1 – 23.5
(Reference value) {206 – 215} {205 – 240}
*1. Cylinder with buffer ring
20-12 HD465-7, HD605-7

(12)

ponent value value

{kg} {23.8 ± 3} {23.8 ± 3}
Brake pedal
Travel (Start of depressing

o Full) mm 40 ± 5 40 ± 10
Operating force • At point 10 mm from tip of lever N 5.9 – 9.8 3.0 – 14.7
Retarder
{kg} {0.6 – 1.0} {0.3 – 1.5}

control
lever
0 0
Travel deg 0 – 78 –2
0 – 78 –4

Emergency brake pedal

{kg} {30.2 ± 3} {30.2 ± 3}
• Initial speed: 32 km/h

46 ton • Distance from starting to lose
payload Max. 22.3 Max. 22.3
Service speed to stopping
brake m
braking • Max. hydraulic pressure
distance Rear: 9.8 MPa {100 kg/cm2}
Empty Front: 17.6 MPa {180 kg/cm2} Max. 17.0 Max. 17.0
Front • Engine: Stopped 17.6 ± 1.2 17.6 ± 1.2

• When first operated {180 ± 12} {180 ± 12}
Brake
actuating Rear 9.8 ± 0.7 9.8 ± 0.7
pressure (service) {100 ± 7} {100 ± 7}
MPa
Rear {kg/cm2} 8.7 ± 0.6 8.7 ± 0.6
Brakes
(retarder) {88.5 ± 6.5} {88.5 ± 6.5}

• Engine: Stopped 9.85 +– 0.49
0.98 9.85 –+ 0.49
0.98
Parking brake releasing
pressure {100.4 +– 510 } {100.4 +– 510 }
• Carrying 46 ton payload

Stopping distance when • Initial speed: 32 km/h m Max. 52.1 Max. 52.1
emergency brake is applied
Operating pressure 17.6 ± 1.2 17.6 ± 1.2

at first operation after Front {180 ± 12} {180 ± 12}
accumulator is
charged MPa 9.8 ± 0.7 9.8 ± 0.7
Brake oil pressure Rear {kg/cm2} {100 ± 7} {100 ± 7}
8.7 ± 0.6 8.7 ± 0.6
Retarder {88.5 ± 6.5} {88.5 ± 6.5}
HD465-7, HD605-7 20-13

(12)

ponent value value
Service brake Apply the brake and set the gear shift Must not move at 1,870 rpm
lever in D and raise the engine speed
Retarder brake gradually. Measure the engine speed Must not move at 1,400 rpm
when the truck starts moving rpm
Parking brake Must not move at 1,670 rpm
Must not move until torque
Emergency brake
Brakes
converter stall speed
Front brake Left side 19.5 3.0

mm
(Pad thickness ) Right side 19.5 3.0
Rear brake Left side Must be in wear gauge range

(Disc wear gauge ) —
Right side Must be in wear gauge range
• Engine: stopped HOLD Max. 29.4 Max. 35.3
• Center of control o RAISE {Max. 3.0} {Max. 3.6}
lever knob RAISE Must return smoothly when
o HOLD engine is running at high idle
HOLD Max. 29.4 Max. 35.3
o FLOAT N {Max. 3.0} {Max. 3.6}
Operating force {kg}
Dump lever

o HOLD {Max. 3.0} {Max. 3.6}
o LOWER {Max. 3.0} {Max. 3.6}
LOWER Must return smoothly when
o FLOAT engine is running at 2,000 rpm
• Engine: stopped RAISE
o HOLD 44.8 ± 1.9 44.8 ± 1.9
• Center of control
Travel mm
lever knob HOLD
o LOWER 44.8 ± 1.9 44.8 ± 1.9
• Oil temperature: 20.1 – 21.1 19.6 – 22.6

Dump valve
45 – 55°C At high idle (2,270 rpm) {205 – 215} {200 – 230}

Relief pres-
sure
At low idle (750 rpm) 18.6 – 19.6 18.6 – 19.6
(Reference value) {190 – 200} {190 – 200}
MPa
Dump EPC valve
{kg/cm2} 3.4 ± 0.49 3.4 ± 0.49

At high idle (2,270 rpm) {35 ± 5} {35 ± 5}
Relief pres-
sure ( root
pressure)
At low idle (750 rpm) 2.6 ± 0.49 2.6 ± 0.49
Lifting speed • Oil temperature: 45 – 55°C 11.5 ± 1.5 11.5 ± 1.5

• Engine speed: 2,000 rpm sec.
Lowering speed • Use FLOAT when lowering 10.5 ± 1.5 10.5 +– 1.0
2.0
Body

• Set with No. 2 cylinder extended
Hydraulic drift mm Max. 85 170
200 mm
• Hydraulic drift after 5 minutes
20-14 HD465-7, HD605-7

(12)
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......................................................................................................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
Setting of card-type payload meter after installation or replacement ....................................................... 20-160-2
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

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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
Coolant, 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 790-261-1204 (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
790-261-1204 (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 799-261-1204 (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

(11)
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
790-261-1204 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 set load F1 6162-23-4500 Barring device 1
1 799-201-9001 Handy smoke checker 1

Exhaust color G Bosch index: 0 – 9
2 795-502-1350 Smoke meter 1
1 792-610-1000 Suspension tool 1
2 • 792-610-1130 • Pump assembly 1
3 • 792-610-1110 • Hose 1 H2 – H6
Pump assembly KIT
4 • 792-610-1120 • Joint 1 part No. 792-610-1100
5 • 07020-21732 • Fitting 1
6 • 792-610-1140 • Joint 1
Suspension cylinder of H 7 • 792-610-1250 • Valve assembly 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 assembly 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

(11)
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 type personal 1 OS: Windows 98/2000

available computer
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}
Travel, 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 assembly 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 assembly 1 For DT connector
3 799-601-9300 T-adapter assembly 1 For DT connector (For 24, 40 pin)
4 795-799-5520 Socket (S) 1 For speed sensor
5 795-799-5530 Socket (C) 1 For fuel temperature sensor

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

(11)
Sym-
bol
Atmosphere pressure sensor
7 795-799-5460 Cable 1 Fuel rail pressure sensor
(Cummins Part No.: 3824774) Timing rail actuator
Fuel pump actuator
Sensor, wiring harnesses T 8 795-799-5470 Cable 1 Fuel rail actuator
(Cummins Part No.: 3824775) Engine oil pressure sensor
Timing rail pressure sensor
9 795-799-5480 Cable 1 Boost pressure sensor
(Cummins Part No.: 3824776) Fuel pump pressure sensor
SKETCH OF SPECIAL TOOL

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these drawings.
K Plug
HD465-7, HD605-7 20-101-4

(11)
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.
a Measure the engine speed under the follow- a Monitoring items
ing condition. (1) Code No. 01001:
• Engine coolant temperature: Within operat- Engine speed
ing range (2) Code No. 30100:
• Torque converter oil temperature: Within oper- Torque converter oil temperature
ating range a 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.
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
• Monitoring code: 01001 (Engine speed)
a The unit of displayed engine speed is 1 rpm.
2) Start the engine and raise the temperature of

the hydraulic oil and torque converter oil.
a Torque converter oil temperature:
60 – 80°C
a 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.
a If the gearshift lever is operated to any
2. Measuring low idle speed position other than the D position, the
1) Set the shift lever N and dump lever in machine may move off even if the brake
HOLD. is being depressed, so always measure
2) Start the engine and set the accelerator at the D position.
pedal in the low idle position and measure 4) Depress the accelerator pedal gradually, run
the engine speed. the engine at high idle and stall the torque
converter to raise the torque converter oil
3. Measuring high idle speed temperature.
1) Set the shift lever N and dump lever in
HOLD. There is danger of damage to the inter-
2) Start the engine and set the accelerator nal parts of the transmission, so never
pedal in the high idle position and measure operate the gearshift lever to any posi-
the engine speed. tion other than the D position during
the stall operation.
5) When the torque converter oil temperature
goes above 90°C, run the engine immedi-
ately at low idle 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

(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
6) Run the engine at a mid-range speed, and

when the torque converter oil temperature
goes down to approx. 80°C, run at low idle.
a Keep the gearshift lever at the N position.
7) Repeat Steps 3 – 6 and equalize the oil tem-
perature in the torque converter and trans-
mission.
8) At the same time as repeating Steps 3 and 4,
measure the stall speed when the torque
converter oil temperature is 80°C.
a Measure the stall speed 2 or 3 times.
a The stall speed may vary according to the

following conditions, so always measure the
stall speed at the time of delivery.
i) Variations according to the engine serial
number
ii) Variations in engine output due to atmo-
spheric pressure and temperature
iii) Variations due to consumption torque of
accessories
iv) Variations due to features of the torque
converter
v) Variations according to the method of
measuring the stall
HD465-7, HD605-7 20-103

(10)
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).
Nut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}
20-104 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL (Measuring with measuring instruments)

1. Remove engine oil pressure measurement plug
PRESSURE (1).
Special tool list

Symbol Part No. Part Name
1 799-101-5002 Hydraulic tester
790-261-1204 Digital type hydraulic tester
C
2 Hydraulic tester
799-401-2320
(1.0MPa {10kg/cm2})
a Measure the engine oil pressure under the fol-

lowing conditions.
• Engine oil temperature: Min. 80°C
• Coolant temperature: Within operating range
(Measuring with monitor panel)

a It is also possible to check the engine oil pres- 2. Fit nipple [1] of hydraulic tester C1, then connect
sure with the "Monitoring function of service to hydraulic tester C2.
mode 1" of the machine monitor (EMMS). For
details of the method of operation, see SPECIAL
FUNCTIONS OF MONITOR PANEL (EMMS).
• Monitoring code: 37200 (Engine oil pressure)
a The engine oil pressure is displayed in units of 1
kPa.
a For the method of measurement, see MEASUR-
ING WITH MEASURING INSTRUMENTS.
3. Start the engine, and measure the oil pressure at

low idle and high idle.
4. After completing the measurement, remove the

measuring equipment and set to the original con-
dition.
HD465-7, HD605-7 20-105

(11)
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY (Measuring with measuring tool)

1. Remove air supply pressure measurement plug
PRESSURE (1).
(BOOST PRESSURE)
Special tool list
Symbol Part No. Part Name Remarks
A 799-201-2202 Boost gauge kit –101 – 199.9kPa

{–760 – 1,500mmHg}
Be careful not to touch any hot parts when

removing or installing the measuring tools.
a Measure the air supply pressure (boost pres-
sure) under the following conditions.
• Torque converter oil temperature: Within oper-
ating range
2. Fit nipple of boost gauge kit A, then connect
• Hydraulic oil temperature: 45 – 55°C
gauge.
(Measuring with monitor panel)
1. Change the machine monitor to Service mode 1
and display the following 2 items simultaneously
with the monitoring function.
a Monitoring items
(1) Code No. 01001: Engine speed
(2) Code No. 36500: Boost pressure
3. Run the engine at a mid-range speed or above to

bleed the oil from the hose.
a Insert the connection of the hose and pres-
sure gauge about half way, repeat the action
to open the self-seal portion at the hose end,
and bleed the oil.
a If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
a For the method of measurement, see MEA-
used.
SURING WITH MEASURING INSTRU-
a If there is oil inside the hose, the gauge will
MENTS.
not work, so always bleed the oil.
20-106 HD465-7, HD605-7

(1)
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
4. Run the engine at high idle to stall the torque

converter, and measure the air supply pressure
(boost pressure).
a For details of the procedure for stalling the
t o r q u e c o n v e r t e r, s e e M E A S U R I N G
TORQUE CONVERTER STALL SPEED.
a The air supply pressure (boost pressure)
should be measured with the engine running
at rated output. However, when measuring in
the field, a similar value can be obtained at
torque converter stall speed.
5. After completing the measurement, rermove the

dition.
HD465-7, HD605-7 20-107

(9)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
Special tool list
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.
a Measure the exhaust temperature under the fol-
3. Method of periodic measurement for preventive
lowing conditions.
maintenance service.
a To prevent the torque converter from over-
• Torque converter oil temperature: Within oper-
heating, use the full stall (torque converter
ating range
stall + hydraulic relief) to stabilize the
• Hydraulic oil temperature: 45 – 55°C
exhaust temperature, then stall only the
torque converter and measure the tempera-
Method using measuring equipment
ture.
1. Remove exhaust temperature measurement
1) Turn the power mode switch to the HIGH
plug (1).
POWER position.
the coolant 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
position other than the D position, the
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 idle and stall the torque
converter. At the same time, operate the
2. Install sensor [1], then connect to digital temper- dump lever to the LOWER position and
ature gauge B. relieve the oil pressure (full stall).
a Clamp the wiring harness of the temperature a Continue until the exhaust temperature
gauge at a suitable place to prevent it from reaches the standard value of 670°C.
touching any hot part.
There is danger of damage to the inter-
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

(10)
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 idle, then return
the gearshift lever to the N position.
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
automatically recorded.) (1) Code No. 01001 : Engine speed
a The exhaust temperature largely depends on (2) Code No. 42601 : Exhaust temperature
the outside air temperature (intake air tem- (rear)
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)

dition.
a For details of the method of measuring, see

METHOD USING MEASURING EQUIP-
MENT.
HD465-7, HD605-7 20-109

(10)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Special tool list
799-201-1504 Blow-by checker 0 – 4.9 MPa

{0 – 500 mmH2O}
Method using measuring equipment

1. Install nozzle and hose [1] to blow-by hose (1),
then connect to blow-by checker E.

dition.
Method using monitoring

a 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 a Monitoring items
coolant 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
position other than the D position, the
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 idle and stall the torque converter,
and measure the blow-by pressure.
There is danger of damage to the internal
parts of the transmission, so never operate a For details of the method of measuring, see
the gearshift lever to any position other METHOD USING MEASURING EQUIP-
than the D position during the stall opera- MENT.
tion.
a After completing the measurement, run the
engine at low idle, then return the gearshift
lever to the N position.
20-110 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF
INJECTOR
Special tool list
J 795-799-5510 Heat gun
a 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.

a 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". a 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
a Make marks to the same points on the upper
a 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-
tion value 105 67 79 112 94 102
Average
value 93
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.
a 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
86 96 73 91 94 103
caused by difference in the measuring point. value
Compensa- 106 101 73 91 99 123
tion value
4. Run the engine at low idle. Average
99
value
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
a 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

(10)
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

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.
2 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)
7. Disconnect 2 connectors (4) (POW) and (SIG) of 3 Holder mounting bolt:
the engine. 1st time: 24.5 – 34.3Nm {2.5 – 3.5kgm}
a After this step, the fuel pump does not supply 2nd time: Tighten by 90 – 120°
2 Threads and seat of rocker arm assembly
fuel to the injectors.
mounting bolt: Engine oil (EO30CD)
3 Rocker arm assembly mounting bolt:
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

(10)
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
790-261-1204 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

(11)
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
3) Run the engine at low idle and check that the

source voltage of the fuel pump pressure
sensor is in the following range.
a Source voltage of sensor (CN-PMPR
connector between (A) – (B)): 4.75 –
5.25 V
4) Run the engine at each speed in the follow-
ing table and check that the signal voltage of
the fuel pump pressure sensor is in the cor-
responding range shown in the same table.
a Signal voltage of sensor (CN-PMPR con-
nector between (C) – (D)):
Table 1 Engine speed and signal voltage
Engine Fuel pump outlet port
speed Signal voltage pressure (Reference)
1.23 ± 0.14 MPa 3) Start the engine, switch the machine monitor
1,000 rpm 1.68 ± 0.21 V {12.6 ± 1.43 kg/cm2} to the display of "Monitoring function of ser-
1.57 ± 0.14 MPa vice mode 1", and prepare for measuring the
1,300 rpm 3.00 ± 0.21 V {16.0 ± 1.43 kg/cm2} engine speed.
1.78 ± 0.14 MPa a For details of the method of operation, see
1,500 rpm 3.26 ± 0.21 V {18.15 ± 1.43 kg/cm2}
SPECIAL FUNCTIONS OF MACHINE
MONITOR.
2. Measuring with pressure gauge (directly) • Monitoring code: 010 (Engine speed)
1) Fit adapter K3 to nipple (2) for measuring the a The engine speed is displayed in units of
pump outlet port pressure. 1 rpm.
2) Install nipple [1] of hydraulic tester C1 to nip- 4) Run the engine at the speed shown in Table
ple (2) and connect them to hydraulic tester 1 and check that the pump outlet port pres-
H1. sure is in the range shown in the table 1.
HD465-7, HD605-7 20-113

(10)
MEASURING FUEL PUMP INLET PORT 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 a Insert the connection of the negative pres-
sure gauge and hose about halfway, repeat
Special tool list the action to open the self-seal portion at the
Symbol Part No. Part Name hose end to bleed the oil.
799-101-5002 Hydraulic tester a If Pm kit (A) is available, the air bleed cou-
C 1 pling (790-261-1130) inside the kit can be
790-261-1204 Digital hydraulic tester
used.
1 795-799-5550 Adapter
M
a If there is oil inside the hose, the gauge will
Negative pressure gauge
2 795-799-5560 (0 – -0.1 MPa{0 – -1.02 kg/cm2}) not work, so always bleed the oil.
4. Run the engine at full throttle and measure the

1. Fit adapter M1 to pump inlet port pressure mea-
pump inlet port pressure (See Table 1).
suring nipple (1).
2. Fit nipple [1] of hydraulic tester C1 and hose [2] Table 1
to adapter M1 and connect them to negative
Fuel filter Fuel pump inlet port pressure
pressure gauge M2.
New Max. – 13.60 kPa {Max. – 102 mmHg}
Used Max. – 27.10 kPa {Max. – 203 mmHg}
VISUAL INSPECTION OF
RETURN FUEL
a The fuel used for control of the timing rail in the
fuel circuit and the excessive fuel that is not used
injected in the fuel rail are returned from the
injector through the fuel cooler to the fuel tank.
a 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.
a Plug the hole of the fuel tank.
a 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.
a Fuel spillage (Reference)
At low idle: 4 – 6 /min
At high idle: 10 – 12 /min
a If the fuel spillage is extremely low, check the
return piping and fuel cooler for clogging.
20-114 HD465-7, HD605-7

(11)
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

(4)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a If the engine does not start or is difficult to start a Add fuel from the inlet port a (8 places). Por-
after the following operations or conditions, bleed tion b is the outlet port after filterinig (clean
the air from the fuel circuit as follows. side), so never add fuel from portion b.
• When starting the engine for the first time
• After cleaning the fuel tank
• After adding fuel when the engine has stalled
• After replacing the fuel filter (only when the
air is not bled easily)
1. Check that there is ample fuel in the fuel tank.
2. Remove fuel filter (1), fill it with fuel, then install it

again.
a Carry out this operation only if the fuel filter
has been replaced.
a If the fuel filter is not to be replaced, there is
danger of dirt getting in, so do not remove
the fuel filter.
HD465-7, HD605-7 20-117

(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Crank the engine with the starting motor, push air

bleed the valve (1), and bleed the air from the
vent circuit.
a There is no problem with starting even if
some air is in the circuit, so if the fuel flows
out the bleeding operation is completed.
4. Start the engine and run at low idle.

a The injector is an open circuit, so while the
engine is running the air remaining in the cir-
cuit is released from the injector to the inside
of the engine or the fuel tank.
a After the engine is started, the engine rota-
tion will be slightly unstable until the air
remaining in the circuit is completely bled, so
continue to run the engine at low idle until it
stabilizes.
a If the engine will still not start after the above

operation, fill the fuel pump with fuel as follows.
1) Remove air bleeding valve (1).
2) Fill with clean fuel through the hole in the
valve until it overflows.
a Amount of fuel to add: Approx. 30 cc (ref-
erence)
3) Install air bleeding plug (1).
Air bleeding plug: 12.7 Nm {1.3 kgm}
4) Crank the engine with the starting motor.
20-118 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST 2. Measuring with Smoke Meter G2

1) Keep the dump body raised and insert the
COLOR probe of smoke meter G2 in the joint of the
exhaust pipe and dump body and fix it to the
Special tool list exhaust pipe.
Symbol Part No. Part Name Remarks 2) Connect the air hose and the socket of the
Handy smoke probe hose and accelerator switch to smoke
1 799-201-9001
G checker Bosch index: 0 – 9 meter G2.
2 795-502-1350 Smoke meter a Keep the pressure of the air supply
below 1.5 MPa (15 kg/cm2).
Be careful not to touch any hot parts when 3) Connect the power cord to the AC socket.
removing or installing the measuring tools. a Before connecting the cord, check that
When measuring with a handy smoke meter, the power switch of the smoke meter is
avoid standing against the exhaust gas and OFF.
insert the exhaust gas suction port into the 4) Loosen the cap nut of the suction pump, and
exhaust pipe. fit the filter paper.
a When measuring in the field where there is no air 5) Turn the power switch of smoke meter G2
or electric power supply, use handy smoke ON.
checker G1; when recording formal data, use
smoke meter G2.
1. Measuring with Handy Smoke Checker G1

1) Install filter paper to handy smoke checker
G1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
the coolant to the operating range.
4) Keep the dump body raised and set handy
smoke checker G1 to the joint of the exhaust
pipe and dump body.
5) Accelerate the engine suddenly, and operate

the handle of handy smoke checker G1 while
running at high idle to collect the exhaust gas
on the filter paper.
6) Remove the filter paper and compare it with
the scale supplied to judge the condition.
HD465-7, HD605-7 20-119

(11)
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).
a Insert the feeler gauge and turn the adjust-
Special tool list ment screw until the clearance is a sliding fit.
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.
a 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.
center, and align [1.6TOP] line a on the damper
You may adjust the valves marked with q when
with pointer (2).
the No. 1 cylinder is at the compression top dead
a Use a barring device F1 on the flywheel
center and adjust the valves marked with Q
housing to carry out cranking.
when the No. 6 cylinder is at the compression
a At compression top dead center, the rocker
top dead center, referring to the following valve
arm of the No.1 cylinder can be moved by
arrangement.
hand an amount equal to the valve clear-
• Firing order: 1–5–3–6–2–4
ance. If the rocker arm does not move, it is
a Valve clearance (at cold).
not at compression top dead center, so
Intake valve : 0.32 ± 0.2 mm
rotate the crankshaft one more turn.
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

(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
Testing
• Measure deflection a when a point midway
between the alternator pulley and idler pulley is
pressed with a finger.
a Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting
a If the deflection is not correct, adjust as follows.
1. Loosen the 2 alternator (1) mounting bolts and 1

lock bolt (2) for the adjustment rod.
2. Loosen locknut (3), then turn adjustment nut (4)

to move alternator (1) and adjust the belt ten-
sion.
3. Tighten the 2 alternator mounting bolts and 1

lock bolt for the adjustment rod.
Alternator mounting bolt (4):

65 – 85 Nm {6.7 – 8.7 kgm}
Alternator locknut (1):

147 – 247 Nm {15 – 25 kgm}
HD465-7, HD605-7 20-121

(1)
TESTING AND ADJUSTING, AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR BELT TENSION
TESTING AND ADJUSTING,

AIR CONDITIONER
COMPRESSOR BELT TENSION
Testing
• Measure deflection a when a point midway
between the air conditioner compressor pulley
and idler pulley is pressed with a finger.
a Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting
a If the deflection is not correct, adjust as follows.
1. Loosen the mounting bolts (2) of air conditioner

compressor bracket (1).
2. Loosen locknut (3), then turn adjustment nut (4)
to move air conditioner compressor bracket (1)
and adjust the belt tension.
3. After completing the adjustment, tighten air con-

ditioner compressor mounting bolts.
20-122 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
Special tool list a Table of oil pressure measurement port posi-

Symbol Part No. Part Name Remarks tions and gauges to use
Pressure gauge
No. Measurement location Gauge
799-101-5002 Analog hydraulic 2.5, 5.9, 39.2, (MPa{kg/cm2})
meter 58.8 MPa {25, 60,
C1 400, 600 kg/cm2} 1 Main relief pressure 5.9{60}
Digital hydraulic Pressure gauge 2 Torque converter inlet port pressure 2.45{25}
790-261-1204 58.8 MPa
meter
{600 kg/cm2} 3 Torque converter outlet port pressure 2.45{25}
4 Torque converter lock-up clutch pressure 5.9{60}
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission 4th clutch pressure 5.9{60}
11 Transmission R clutch pressure 5.9{60}
5A- Each clutch pilot pressure 5.9{60}
11A
a The transmission lubrication pressure is repre-

sented by the torque converter outlet port pres-
sure, so there is no need to measure it.
HD465-7, HD605-7 20-123

(11)
Stop the machine on a level ground, turn the Items related to torque converter
parking brake switch PARKING, and put 2. Measuring torque converter inlet oil pressure
chocks under the tires.
Stop the engine and wait until the oil tempera- Raise the dump body and lock it with the safety
ture lowers sufficiently before installing and pin.
removing the measuring instruments. Take care not to "get burned", since the oil
When measuring the oil pressure while the temperature is high.
machine is traveling, secure a wide travel area When removing and installing a plug or an oil
and take care of the safety around the machine. pressure gauge, stop the engine.
1) Referring to TESTING MAIN RELIEF OIL
PRESSURE, check that there is not abnor-
Whole power train
mality.
1. Measuring main relief pressure
2) Remove plug (2) and install tool C (2.45 MPa
Raise the dump body and lock it with the safety {25 kg/cm2}) (including C1, [1]).
pin.
Take care not to "get burned", since the oil
temperature is high.
When removing and installing a plug or an oil
pressure gauge, stop the engine.
1) Raise the transmission oil temperature.
a Oil temperature for measurement:
60 – 80°C
{60 kg/cm2}) (including C1, [1]).
3) Start the engine and measure the oil pres-

sure at high idle.
4) After completing the measurement, remove
the measuring equipment and set to the orig-
inal condition.
3) Start the engine and set the gear shift lever in

the "N", and then measure the oil pressure at
low idle and high idle.
inal condition.
20-124 HD465-7, HD605-7

(10)
3. Measuring torque converter outlet oil pres- 4. Measuring torque converter lock-up clutch
sure and pilot pressure
1) Raise the dump body, then lock with safety
Raise the dump body and lock it with the safety
pin.
pin.
2) Remove hydraulic oil pressure measuring
Take care not to "get burned", since the oil
plug (4), (4A) and install the nipple and
temperature is high.
hoses [1] for measurement.
When removing and installing a plug or an oil
pressure gauge, stop the engine.
1) Referring to TESTING MAIN RELIEF OIL
PRESSURE, check that there is not abnor-
mality.
{25 kg/cm2}) (including C1, [1]).
3) Lower the dump body and set to the original

condition.
4) Connect oil pressure gauge C1.
the torque converter oil to the operating
range.
6) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set
the gearshift lever to position L.
7) Release the brake, travel at high idle, and
measure the oil pressure when the lock-up
pilot lamp lights up.
In F1, a maximum travel speed of
approx. 11.5 km/h is reached, so check
carefully that the surrounding area is
safe.
3) Start the engine and measure the oil pres-

sure at high idle.
inal condition.

inal condition.
HD465-7, HD605-7 20-125

(10)
Transmission related 5. Measuring transmission Lo clutch and pilot

a Table of gearshift lever positions, speed pressure
ranges, and clutches actuated 1) Raise the dump body, then lock with safety
pin.
Gearshift lever Speed Clutches
2) Remove hydraulic oil pressure measuring
R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R
plug (5), (5A) and install the nipple and
F1 hoses [1] for the measurement.
F2
F3
F4
F5
F6
F7
N
R
a The mark indicates the speed ranges that are

actuated for each position of the gearshift lever.
a The mark and mark indicate the clutches
that are actuated for each travel speed.
a The mark indicates the speed range when 3) Lower the dump body and set to the original
measuring the oil pressure for each clutch. condition.
4) Connect oil pressure gauge C1.
the torque converter oil to the operating
range.
6) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set
the gearshift lever to position L.
7) Release the brake and measure the oil pres-
sure when traveling at high idle.
approx. 11.5 km/h is reached, so check
carefully that the surrounding area is
safe.

inal condition.
20-126 HD465-7, HD605-7

(10)
6. Measuring transmission Hi clutch and pilot 7. Measuring transmission 1st clutch and pilot
pressure pressure
1) Raise the dump body, then lock with safety 1) Raise the dump body, then lock with safety
pin. pin.
2) Remove hydraulic oil pressure measuring 2) Remove hydraulic oil pressure measuring
plug (6), (6A) and install the nipple and plug (7), (7A) and install the nipple and
hoses [1] for the measurement. hoses [1] for the measurement.
3) Lower the dump body and set to the original 3) Lower the dump body and set to the original
condition. condition.
4) Connect oil pressure gauge C1. 4) Connect oil pressure gauge C1.
5) Start the engine and raise the temperature of 5) Start the engine and raise the temperature of
the torque converter oil to the operating the torque converter oil to the operating
range. range.
6) Turn the parking brake switch TRAVEL, 6) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set depress the parking brake pedal, then set
the gearshift lever to position 3. the gearshift lever to position L.
7) Release the brake, travel at high idle, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idle.
cator shows "3".
In F3, a maximum travel speed of approx. 11.5 km/h is reached, so check
approx. 21.5 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe.
inal condition.

inal condition.
HD465-7, HD605-7 20-127

(10)
8. Measuring transmission 2nd clutch and pilot 9. Measuring transmission 3rd clutch and pilot
pressure pressure
pin. pin.
range. range.
the gearshift lever to position 2. the gearshift lever to position 4.
7) Release the brake, travel at high idle, and 7) Release the brake, travel at high idle, and
measure the oil pressure when the shift indi- measure the oil pressure when the shift indi-
cator shows "2". cator shows "4".
In F2, a maximum travel speed of In F4, a maximum travel speed of
approx. 16.0 km/h is reached, so check approx. 29.5 km/h is reached, so check
carefully that the surrounding area is carefully that the surrounding area is
safe. safe.
inal condition.

inal condition.
20-128 HD465-7, HD605-7

(10)
10. Measuring transmission 4th clutch and pilot 11. Measuring transmission R clutch and pilot
pressure pressure
pin. pin.
range. range.
the gearshift lever to position 6. the gearshift lever to position R.
7) Release the brake, travel at high idle, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idle.
cator shows "6".
In R, a maximum travel speed of
In F6, a maximum travel speed of approx. 12.0 km/h is reached, so check
approx. 52.5 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe.
inal condition.

inal condition.
HD465-7, HD605-7 20-129

(10)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
a There are 3 speed sensors installed to the trans- 3. Secure nut (3) with sensor (1).
mission. Adjust each sensor as follows.
Nut: 49.0 – 68.6Nm {5 – 7 kgm}
CN3: Input shaft speed sensor
CN4: Intermediate shaft speed sensor
CN5: Output shaft speed sensor
1. Screw in until the tip of sensor (1) contacts the

face or tip of the tooth of gear (2).
a Before installing, check that the tip of the
sensor is not scratched and that there are no
iron particles sticking to the sensor tip.
Thread portion: Gasket sealant (LG-5)
2. Turn back sensor (1) 1/2 – 1 turn from this posi-

tion.
a Adjust clearance a between the tip of the
sensor and the tip of the gear tooth to 0.75 – 4. After completing the adjustment, check that the
1.0 mm. each transmission shaft speed is displayed nor-
mally by using the monitoring function of the
machine monitor.
SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
20-130 HD465-7, HD605-7

(1)
TESTING AND ADJUSTING INSPECTING BRAKE OIL PRESSURE
INSPECTING BRAKE OIL 4) Measure the cut-out pressure at high idle.

• Read the ACC oil pressure (front or rear)
PRESSURE when it stops rising at the highest point
(Approx. 20.6 MPa {Approx. 210 kg/
Special tool list
cm2}) after the cut-in pressure.
Pressure gauge (Measuring with diagnosing devices)
Analog hydraulic 2.5, 5.9, 39.2,
799-101-5002
meter 58.8 MPa {25, 60,
1) Stop the engine and remove plug (4) (18, P:
C1 400, 600 kg/cm2} 1.5). Connect nipple J and hose [1] and
Pressure gauge install oil pressure gauge C1 (Oil pressure
Digital hydraulic
790-261-1204
meter
58.8 MPa gauge: 39.2 MPa {400 kg/cm2}).
{600 kg/cm2}
18 × 1.5
J 566-35-43561 Nipple
(female: PT 1/8)
Stop the machine on a level place, apply the

parking brake, and set chocks under the tires
securely.
1. Measuring ACC charge oil pressure

(Measuring with monitor)
1) Set the machine monitor in service mode 1
and display the following 2 items simulta-
neously with the monitoring function.
a Monitoring items
(1) Code No. 35500:
ACC oil pressure (Front)
(2) Code No. 35501:
ACC oil pressure (Rear)
2) Start the engine.

3) Measure the cut-in pressure at high idle.
i) Press and release the brake pedal
repeatedly to lower the oil pressure in the
accumulator.
ii) Read the lower one of the ACC oil pres-
sures (front or rear) when it starts rising
after it reaches the bottom (Approx. 14.2
MPa {Approx. 145 kg/cm2}).
a For the method of measurement, see
MEASURING WITH MONITOR, 2) – 4).
(Read the pointer of the oil pressure
gauge, however.)
HD465-7, HD605-7 20-131

(11)
TESTING AND ADJUSTING INSPECTING BRAKE OIL PRESSURE
2. Rear brake operating pressure 4. Front brake operating pressure

1) Remove air bleeder (1) and install tool C1 1) Remove air bleeder (3) and install tool C1
[Oil pressure gauge: 39.2 MPa {400 kg/ [Oil pressure gauge: 39.2 MPa {400 kg/
cm2}]. cm2}].
2) Operate the brake pedal and retarder control 2) Operate the brake pedal and measure the oil
lever and measure the oil pressure. pressure.
a After finishing measurement, bleed air, a After finishing measurement, bleed air,
r eferr ing to BLEE DING A IR FRO M r efe rr ing to B LEEDING AIR FROM
BRAKE CIRCUIT on the next page. BRAKE CIRCUIT on the next page.
3. Parking brake releasing pressure

1) Remove air bleeder (2) and install tool C1
[Oil pressure gauge: 39.2 MPa {400 kg/
cm2}].
2) Turn OFF the parking brake switch (Release
the parking brake) and measure the oil pres-
sure.
a After finishing measurement, bleed air,
r eferr ing to BLEE DING A IR FRO M
BRAKE CIRCUIT on the next page.
20-132 HD465-7, HD605-7

(1)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE

CIRCUIT
a If any brake circuit device was removed and
installed or if the transmission and brake cooling
oil was replaced, bleed air from the brake circuit
according to the following procedure.
Stop the machine on a level ground and set
chocks under the tires securely.
1. Rear brake
a Bleed air from the slack adjuster side first,
then bleed air from the wheel brake side.
1) Using a vinyl tube for bleeding air, depress 2. Parking brake

the brake pedal and loosen air bleeder screw a Bleed air from the differential top block side
(1) or (2) by 3/4 turns. Keep depressing the first, then bleed air from the wheel brake
brake pedal until bubbles do not come out of side.
the bleeder any more. When bubbles do not 1) Using a vinyl tube for bleeding air, turn OFF
come out any more, tighten (close) the the parking brake switch (release the parking
bleeder and release the pedal. brake) and loosen air bleeder screw (4) by 3/
2) Pull the retarder control lever and loosen air 4 turns.
bleeder screw (1) or (2) by 3/4 turns. Keep 2) When bubbles do not come out of the
pulling the retarder control lever until bubbles bleeder any more, tighten (close) the bleeder
do not come out of the bleeder any more. and turn ON the parking brake switch (apply
When bubbles do not come out any more, the parking brake).
tighten (close) the bleeder and release the 3) Bleed air from bleeder (5) on the wheel side
retarder control lever. similarly to step 1) above.
a After finishing bleeding air, tighten (close)
the bleeder and put the cap.
3. Front brake
a Check that the front brake cut switch is
turned OFF.
1) Loosen air bleeder (6) by 3/4 turns and bleed
air similarly to step 1) for the rear brake.
3) Bleed air from bleeder (3) on the wheel side

similarly to step 1) above.
a After finishing bleeding air, tighten (close)
the bleeder and put the cap.
HD465-7, HD605-7 20-133

(10)
TESTING AND ADJUSTING TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF FRONT

BRAKE PAD
Special tool list
b 566-98-41410 Gauge Tools on truck
Stop the machine on level ground, apply the

parking brake, and put chocks under the tires.
1. Visual check
Check visually, and if the pad has reached the
wear limit line, replace the pad.
2. Checking with gauge

1) Depress the brake pedal, keep the pad (1)
pressed against the disc (2), then insert
inspection gauge b into indicator hole d of
the caliper (3).
2) If the stepped part of the gauge contacts the
mouth of the hole, the pad has reached the
wear limit, so replace it.
e: Remaining thickness up to wear limit
a Replace the pads on the left and right sides
at the same time.
a The pad wear is not the same for both left
and right sides, so check the wear of all
pads.
20-134 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR

BRAKE DISC
Stop the machine on level ground, turn the
parking brake switch PARKING, and put
chocks under the tires.
Carry out the inspection when the brake oil
temperature is less than 60°C.
When the disk comes close to the wear limit,
carry out the inspection more frequently. Be
sure to carry out inspection of the retarder
braking performance at the same time.
1. Check that the brakes other than parking brake

are not being actuated.
2. Stop the engine.
3. Remove cap nut (1) of the gauge.
6. Install cap nut (1) of the gauge.

Cap nut: 19.6 Nm {2.0 kgm}
4. Push in the rod (2) of the gauge until it contacts

the piston and judge the amount of wear.
a With a new machine, adjust so that inner
(deeper) end a of groove D on the rod (2) is
aligned with the end face of guide (3).
The adjustment position will move out of
alignment, so do not loosen locknut (4) of
guide (3) except when replacing the disc.
a Outer end b of groove D indicates the wear
limit for the disc. If it is inside guide (3) totally
[If it reaches the end face of guide (3)], the
disc has reached the wear limit.
HD465-7, HD605-7 20-135

(10)
TESTING AND ADJUSTING METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY
METHOD OF RELEASING
PARKING BRAKE IN AN
EMERGENCY
a If the parking brake cannot be released because
of a trouble in its electric or hydraulic system,
release it tentatively according to the following
procedure.
If the hydraulic system has a trouble, the wheel
brake probably does not work normally.
Accordingly, be sure to tow the machine at low
speed after releasing the parking brake.
When releasing the parking brake, stop the
machine on a level place and make sure of the
safety around it. If it is obliged to release the
parking brake on a slope in an emergency, put
chocks under the tires securely.
When releasing the parking brake, stop the
engine.
1. Remove plugs (1) (10 pieces).

a Prepare a container to receive the oil flowing
out of the plug holes.
Tightening torque for plug:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2. Prepare 10 sets of bolt (2) (01017-51230),

washer (3), and nut (4) for releasing the parking
brake manually and tighten the bolts alternately
and evenly to release the parking brake.
a Tighten nuts (4) to pull piston (5) and release
the parking brake.
20-136 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER

FRONT SUSPENSION
CYLINDER
Special tool list
1 792-610-1000 Suspension tool
2 •792-610-1130 Pump assembly H2 – H6
: Pump assembly
3 •792-610-1110 Hose Kit No.
4 •792-610-1120 Joint : 792-610-1100
5 •07020-21732 Fitting
6 •792-610-1140 Joint
7 •792-610-1250 Valve assembly H7 – H13 a With the truck empty, starting switch ON,
H : Charging tool
8 •792-610-1260 Nipple assembly parking brake OFF, and hoist control
9 •792-610-1480 Stem Kit No. lever at the FLOAT position, check that
: 792-610-1200
10 •792-610-1640 Joint the cylinder of the variable damper valve
Regulator
is in the soft mode.
11 •792-610-1400
assembly a If the cylinder of the variable damper
24.5 MPa valve is not in the soft mode when check-
12 •792-610-1430 Gauge
{250 kg/cm2} ing, operate as follows to switch to the
13 •792-610-1440 Gauge 9.81 MPa soft mode.
{100 kg/cm2} i) Use the retarder brake (Note 1) and
drive the machine several times
a Stop the machine empty on level ground. repeatedly forward and in reverse to
set to the soft mode.
1. Testing length of cylinder Note 1: If the foot brake pedal is
1) Check that the bottom of the cylinder cover is used, the automatic suspen-
within the range e marked by arrows for the sion is automatically set to
cylinder level. the medium mode, and the
resistance of the cylinder
increases, so it takes time to
adjust.
2. Releasing nitrogen gas

1) Front suspension cylinder
i) Set hydraulic jack [1] (50ton) under the
main frame.
ii) Disconnect pressure sensor connector
(2) of valve (1), then loosen the valve (1)
2 – 3 turns.
a When releasing the nitrogen gas, there is
danger that releasing the gas from the
valve core of feed valve (3) will damage
2) Before adjusting the oil level, check the con- the valve core, so remove the gas at the
dition of the variable damper valve. valve (1).
S posision : soft mode a When loosening the valve (1), loosen
H posision: hard mode only the valve itself. Do not loosen the
M posision: medium mode pressure sensor or nipple.
HD465-7, HD605-7 20-137

(10)
a When the valve (1) is loosened, and oil 7) After completion of supplying the oil, remove
and gas spurt out together, tighten the the volume pump, then install feed valve (3).
3 Feed valve:
valve slightly, and allow time for the gas
to escape slowly.
39.2 – 49.0 Nm {4 – 5 kgm}
iii) Operate the hydraulic jack so that dimen-
sion a of the cylinder is the specified
dimension for the oil level.
Dimension a:79 ± 3 mm (Standard)
79 ± 3 mm (With buffer ring)
3. Adjusting of oil level

a Release the nitrogen gas before adjusting
the oil level.
1) Remove feed vavle (3), and install joint H6.
2) Install fitting H5 to joint H4, then connect
hose H3 and volume pump H2.
3) Loosen air bleeding valve (4), then operate
volume pump H2 until no more bubbles
come out with the oil from air bleed side hole
b.
4) When no more bubbles come out with the oil,
tighten air bleeding valve (4).
3 Air bleeding valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5) Remove valve (1), then operate volume
pump H2 until no more bubbles come out
with the oil from the valve (1) mount.
6) When no more bubbles come out with the oil,
tighten the valve (1).
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
20-138 HD465-7, HD605-7

(10)
4. Filling suspension cylinder with gas

1) Remove cap (5) from feed valve (3).
2) Set tool H as shown in the diagram.
a Before installing regulator H11, blow the
connector filter with nitrogen gas at 0.981
MPa {10 kg/cm2} or more to blow out all
dirt or dust. (Dirt or dust in the system
causes failures.)
3) Open valve [2] of the gas cylinder [1], and
check the pressure reading of gauge H12
(internal pressure of gas cylinder).
a The pressure indicated must be at least
0.981 MPa {10 kg/cm2 } higher than the
pressure inside the suspension cylinder
(max. pressure inside suspension cylin-
der: 4.31 MPa {44 kg/cm2}).
4) Turn handle H11a of regulator H11 slowly
clockwise, set the pressure reading of gauge
H13 to 0.981 MPa {10 kg/cm 2 } above the
internal pressure of the suspension cylinder,
then operate valves H7 and H10 to fill the
suspension cylinder with nitrogen gas.
a Fill the left and right cylinders in the
same way.
5) When dimension a of the left and right cylin-
ders reaches the standard value, turn handle
H11a of regulator H11 counterclockwise to
stop the flow of nitrogen gas.
a Standard dimension a: 249 ± 10 mm
6) Turn handle H10a of H10 fully back counter-
clockwise, loosen air bleeding plug H7a of
valve H7, release the gas inside the hose,
then remove tool H.
a Be careful not lose the O-ring of the feed
valve.
HD465-7, HD605-7 20-139

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

(10)
TESTING AND ADJUSTING INVERTED TYPE
TESTING AND ADJUSTING REAR SUSPENSION CYLINDER
TESTING AND ADJUSTING ii) Disconnect pressure sensor connector

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

1) Rear suspension cylinder
i) Set block [2] between the stopper and
axle housing.
Thickness of block: 19 mm
Dimension a : 140 ± 3 mm (Standard)
: 124 ± 3 mm
(With buffer ring)
HD465-7, HD605-7 20-141

(11)
3. Adjusting oil level H13 to 0.981 MPa {10kg/cm 2 } above the

a Release the nitrogen gas before adjusting internal pressure of the cylinder, then oper-
the oil level. ate valves H7 and H10 to fill the cylinder with
1) Remove feed valve (3), and install joint H6. nitrogen gas.
2) Install fitting H5 to joint H4, then connect a Fill the left and right cylinders in the
hose H3 and volume pump H2. same way.
3) Loosen air bleeding valve (1), then operate 5) When dimension "a" of the left and right cyl-
volume pump H2 until no more bubbles inders reaches the standard value, turn han-
come out with the oil from air bleeding valve dle H11a of regulator H11 counterclockwise
(1). to stop the flow of nitrogen gas.
4) When no more bubbles come out with the a Standard dimension a
oil, tighten air bleeding valve (1). : 220 ± 10 mm (Standard)
5) After adding oil, remove the volume pump, : 204 ± 10 mm (With buffer ring)
then install feed valve (3). 6) Turn handle H10a of H10 fully back counter-
clockwise, loosen air bleeding plug H7a of
valve H7, release the gas inside the hose,
then remove tool H.
a Be careful not to lose the O-ring of the
feed valve.
4. Filling suspension cylinder with gas

1) Remove cap (5) from feed valve (3).
2) Set tool H to the feed valve supply as
shown in the diagram.
a Before installing regulator H11, blow the
filter in the connector with nitrogen gas at
0.981 MPa {10 kg/cm2} or more to blow
out all dirt or dust. (Dirt or dust in the sys-
tem causes failures.)
3) Open valve [2] of the gas cylinder [1], and
check the pressure reading of gauge H12
(internal pressure of gas cylinder).
a The pressure indicated must be at least
0.981 MPa {10kg/cm 2 } higher than the
pressure inside the cylinder (max. pres-
sure inside cylinder: 2.74 MPa {28 kg/
cm2}).
4) Turn handle H11a of regulator H11 slowly

clockwise, set the pressure reading of gauge
20-142 HD465-7, HD605-7

(10)
5. Adjusting installed length of cylinder 6. Testing and adjusting dust cover

a Carry out adjustment of the installed length a To protect the rear suspension from stones
of the cylinder with the machine empty and and other objects thrown up by the tires
on level ground. when the machine is traveling, carry out
1) To remove the sliding resistance of the cylin- inspection of the cover and repair or replace
der (catching of bushing or packing), drive it as necessary.
the machine forward approx. 15 m and stop 1) Check visually that there are no cracks or
suddenly, then drive the machine forward breaks in cover (1).
approx. 15 m and stop suddenly, then drive a If the cover is damaged, replace it with a
in reverse to the original position and stop new part.
again suddenly. Repeat this cycle 3 – 4 2) Check that hooks (2) are not missing. (3
times, and finally, allow the machine to stop places)
slowly without depressing the brake. Then a If any hooks are missing, remove all mud
measure the installed length. and dirt, then install hooks.
a Do not use the foot brake when braking 3) Check that band (3) is not loose or missing.
the machine. Use the retarder control a If the band is loose or missing, tighten to
lever to brake, the machine, then check the following torque.
that the suspension is in the soft mode.
2) If the result of the check shows that the Band:
installed length is too long, release nitrogen 6.8 ± 0.49 Ncm {69 ± 5 kgcm}
gas to adjust the length.
a Loosen the valve slightly to release the
nitrogen gas. When doing this, release
only a small amount of gas; do not make
the cylinder move.
a If the nitrogen gas is so released that the
cylinder may move, the installed length
may be below the specified length.
a Do not press the tip of the valve core. If
the tip of the valve core is pressed, the
valve core may be damaged.
3) After releasing nitrogen gas and adjusting
the installed length, repeat Step 1) to check
the installed length again.
4) Repeat the above Steps 1) – 3) to adjust the
cylinder to the specified length.
5) Finally, check that there is no leakage of gas
from the valve core (6), valve, and piston rod
gland.
a Use soapy water to check for leakage of
gas.
a Replace valve core (6) if there is any
leakage of gas from the valve core.
V
a
l
v
e
c
o
r
e
:
HD465-7, HD605-7 20-143

(10)
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER
TESTING AND ADJUSTING (MODE SELECTOR HYDRAULIC CYLNDER)

FRONT SUSPENSION
CYLINDER (MODE SELECTOR
HYDRAULIC CYLNDER)
1. Testing
1) Check that length "a" of hydraulic cylinder
(1) is as specified under the following condi-
tion.
a Condition (Mode S)
(1) Machine is empty.
(2) Starting switch is ON.
(3) Parking brake switch is ON.
(4) Work equipment control lever is at
FLOAT.
a Specified length "a": 352 ± 1 mm
2) Shift the hoist lever from the FLOAT position

to another position and check that hydraulic
cylinder length "a" is not (is longer than)
352 ± 1 mm.
2. Adjusting
1) Remove mounting bolt (2) of hydraulic cylin-
der (1) and disconnect hydraulic cylinder (1).
2) Loosen locknut (3) and adjust mounting 5) Check that the hole of bracket (5) is in the slit
length "a" with rod end. (part "e") in modes S and M.
a Specified length "a": 352 ± 1 mm
3) Install (Return) hydraulic cylinder (1) with
mounting bolt (2).
4) Turn the starting switch to the ON position
and shift the hoist lever from the FLOAT
position to another position and check that
length "a" of hydraulic cylinder (1) is not (is
longer than) 352 ± 1 mm. 10858
(Reference)
• "b" in hard mode : 383 ± 1 mm
• "d" in medium mode : 414 ± 1 mm
20-144 HD465-7, HD605-7

(1)
TESTING AND ADJUSTING HYDRAULIC
TESTING AND ADJUSTING PRESSURE IN STEERING, HOIST CIRCUIT

HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
a 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-
790-261-1204 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 chocks 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. a To INCREASE pressure, turn CLOCK-
WISE
Steering circuit To DECREASE pressure, turn COUN-
1. Measuring hydraulic pressure in steering cir- TERCLOCKWISE
cuit a One turn of the adjustment screw adjusts
1) Raise the hydraulic oil temperature. by 2.45 MPa {25 kg/cm2}.
a 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

(11)
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: 29.4 – 39.2 Nm {3 – 4 kgm} a 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, and move the
PRESSURE IN STEERING CIRCUIT.
dump body to the maximum dump position to
a 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 (39.2
MPa {400 kg/cm2}).
ing the hydraulic pressure in the steering cir-
cuit.
20-146 HD465-7, HD605-7

(10)
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.
a To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
a 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.
Lock nut:
29.4 – 39.2 Nm {3 – 4 kgm}
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

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TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT
TESTING AND ADJUSTING 2) Install nipple C3 and hose [2] 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.
a 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-
790-261-1204 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 [1] and hose [2] 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

(11)
TESTING AND ADJUSTING AIR BLEEDING FROM STEERING CYLINDER
AIR BLEEDING FROM

STEERING CYLINDER
Stop the machine on a level ground, apply the
parking brake, then put chocks under the tires.
Before operating the steering wheel, be sure to

check that there is no one around the front
tires.
a If the hydraulic cylinder was removed and

installed or its hydraulic piping was removed,
breed air from the hydraulic cylinder according to
the following procedure.
1. Start engine, run engine at low idle for 5 minutes.
2. Turn the steering wheel at 30 rpm (2 seconds for

one turn) to the left and right to a point approx.
50 mm from the end of the steering cylinder
stroke.
Repeat this action ten times.
(This action is to prevent damage to the piston
seal caused by compression and combustion of
air in the steering cylinder.)
3. Turn the steering wheel at 30 rpm to the left and

right to the end of the steering cylinder stroke.
Repeat this action four times.
4. Turn the steering wheel as quickly as possible to

the left and right to the end of the steering cylin-
der stroke.
When reaching the end of the stroke at the left
and right, turn the steering wheel immediately in
the opposite direction, and carry out this action
continuously.
Repeat this action ten times in both direction.
HD465-7, HD605-7 20-149

(10)
TESTING AND ADJUSTING PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY
PROCEDURE FOR RAISING When performing this procedure, be sure

DUMP BODY IN EMERGENCY not to go under the dump body but stand
on the ground.
a Special tool list
a The dump body lowers by itself. Keep it at
Symbol Part No. Part Name Remarks safe lowering speed by adjusting the tighten-
K 792T-491-1110 Plug — ing depth tool [K].
a If the dump body cannot be raised because of a 5. After the dump body lowers completely, remove
failure in the controller or electric system, raise it tool [K] and install plug (2).
to dump the load according to the following pro-
Tightening torque of plug:
cedure.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
1. Stop the engine and remove the hydraulic tank

cap to release the residual pressure from the
hoist circuit.
2. Remove plug (1) and tighten tool [K] fully.

a If tool [K] is tightened in fully, the spool is
moved to the rising stroke end.
1) If the engine can be started, start the engine

under this condition, and the dump body
rises.
2) If the engine cannot be started, turn the
emergency steering switch "ON" and raise
the dump body with the hydraulic pressure of
the emergency steering pump.
a Do not operate the emergency steering
pump for more than 90 seconds continu-
ously. If the load cannot be dumped in
90 seconds, cool down the steering
pump, and then operate it again.
3. Stop the engine and remove tool [K] and install

plug (1).
Tightening torque of plug:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
4. When lowering the dump body, remove plug (2)

and tighten tool [K] slowly.
20-150 HD465-7, HD605-7

(10)
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
ADJUSTING BODY 2. Adjusting link length

a If the monitoring voltage is not within the nor-
POSITIONER SENSOR mal range, adjust the length of the link as fol-
lows.
a If the body positioner rod has been disconnected 1) Loosen locknut (1).
and connected again or the body positioner sen- 2) Remove mounting bolt (2).
sor has been removed and installed again, 3) Turn rod end (3) to adjust the length of
inspect and adjust the body positioner sensor as the link (4).
follows. a Standard installing length a: 433 mm.
a HD465-7 #7001 – 7056 a Do not set installing length a less
HD605-7 #7001 – 7020 than 430 mm.
• If the positioner link is changed, adjust it to the HD465-7 #7001 – 7056
same value with following model. HD605-7 #7001 – 7020
HD465-7 #7057 and up a Standard installed length "a" of link:
HD605-7 #7021 and up 440 mm
a Do not reduce length "a" to below
1. Checking sensor input voltage 436 mm.
1) Switch the machine monitor display to the HD465-7 #7057 and up
monitoring function of service mode 1 and HD605-7 #7021 and up
display the body positioner sensor input volt- a Adjust the input voltage as follows.
age. • INCREASE link length to DE-
a Monitoring item CREASE voltage
Code No. 34400: BODY POSITION • DECREASE link length to IN-
a For details of the method of operation, CREASE voltage
see SPECIAL FUNCTIONS OF MA- 4) Install mounting bolt (2).
CHINE MONITOR. 5) Tighten locknut (1).
6) Repeat the checking procedure above to
check that the input voltage is within the nor-
mal range.

3) Operate the dump lever and check the moni-
toring voltage when the dump lever is oper-
ated fully to the LOWER position and RAISE
position.
a When operated fully to LOWER:
0.35 – 0.40 V:
HD465-7 #7001 – 7056
HD605-7 #7001 – 7020
0.38 – 0.44 V:
HD465-7 #7057 and up
HD605-7 #7021 and up
a When operated fully to RAISE:
3.80 – 4.70 V
HD465-7, HD605-7 20-151

(8)
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
3. Calibrating system
Stop the machine on a level ground, apply the

parking brake, then put 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,
run the engine at low idle and keep the dump
control lever in the RAISE position for at
least 5 seconds.
4) Run the engine at high idle and raise the
body to the stroke end. Then, lower the
engine speed to low idle and set the dump
control lever in the FLOAT position to lower
the body to the seating position.
a Repeat the operations of 3) and 4) above
5 – 10 times.
5) Run the engine at high idle and raise the
body to the stroke end. Then, keep the
engine speed at high idle and set the dump
control lever in the LOWER position to lower
the body to the seating position.
a Repeat this operation 5 – 10 times.
20-151-1 HD465-7, HD605-7

(10)
METHOD FOR EMERGENCY ESCAPE WHEN
TESTING AND ADJUSTING THERE IS FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE

IN ELECTRICAL SYSTEM
If any problem occurs in the electrical system of the engine control system or transmission control system, it
may become impossible to start the engine or to move the machine off.
If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system,
move the machine to a safe place, then carry out troubleshooting.
1. When problem occurs in engine control system and engine cannot be started
a Decide the escape method according to the following flowchart.
a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
1 2
Did [Engiine system caution Tow machine to safe place

NO NO
lamp] on machine monitor Is there fuel in fuel tank?
(see note)
flash when engine stopped?
YES YES
3 4 5
Does engine start when fol-
Is following service code lowing fuse is replaced? If there is no relay to re-
displayed or recorded? YES FUA (30A) NO NO place or engine does not
lowing relay is replaced?
C441KK (ENG) BT2 --- No.3 (10A) start, tow machine to safe
R01 (engine start relay)
442KG (ENG) BT2 --- No.15 (20A) place (see note)
BT4 --- No.10 (10A)
NO YES YES
Start engine and move ma-

chine (do not turn electric
power ON except when ab-
solutely necessary)
6 YES 7
Is following service code

YES If there is no controller to
displayed or recorded? Does engine start when en- NO
replace, tow machine to
C111KT gine controller is replaced?
safe place (see note)
C346KT (ENG)
NO
8 9
Is following service code lowing speed sensor is re- If there is no speed sensor
displayed or recorded? YES placed? NO to replace or engine does
C115KZ (ENG) Master speed sensor (SP1) not start, tow machine to
C121LC (ENG) Back-up speed sensor safe place (see note)
(SP2)
NO YES
10
Does engine start when fol- Start engine and move ma-
lowing relay is replaced? YES chine (do not turn electric
R02 (transmission neutral power ON except when ab-
relay) solutely necessary)
NO
Tow machine to safe place

(see note)
Note: If the engine cannot be started and the machine is towed, the parking brake cannot be released by oper-
ating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR
EMERGENCY RELEASE OF PARKING BRAKE.
20-152 HD465-7, HD605-7

(11)
2. When problem occurs in transmission control system and machine cannot be started
a Check the service code and determine the escape method from the following chart.
a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
Failure Condition when failure Escape method Lever position for speed range to Remarks
code occurred move off after escape operation
1380MW Occurrence condition 1 Escape procedure 1 D – L : F2, R : R
Occurrence condition 1:
1500L0 Occurrence condition 2 Escape procedure 2 — Speed range remains fixed;
15G0MW Occurrence condition 2 Escape procedure 3 D – L : F2 when the machine is
moved off again, speed
15H0MW Occurrence condition 3 Escape procedure 1 D – L : F2, R : R range does not shift.
15J0MW Occurrence condition 3 Escape procedure 1 D – L : F2, R : R a When lever is returned to
N, transmission shifts to
15K0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R neutral.
15L0MW Occurrence condition 2 Escape procedure 3 D – L : F1, R : R
Occurrence condition 2:
15M0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R Transmission suddenly
shifts to neutral when the
15N0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R machine is traveling; after
15SBL1 Occurrence condition 3 Escape procedure 1 R:R machine is stopped, trans-
mission stays in neutral
15SBMA Occurrence condition 3 Escape procedure 1 D – L : F2 even when lever is oper-
15SCL1 Occurrence condition 3 Escape procedure 1 D – L : F2, R : R ated, and machine does
not move off.
15SCMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R
15SDL1 Occurrence condition 3 Escape procedure 1 D – L : F2, R : R Occurrence condition 3:
Transmission suddenly
15SDMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R shifts to neutral.
15SEL1 Occurrence condition 3 Escape procedure 1 D – L : F1 Occurrence condition 4:
15SEMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R After engine is started,
transmission stays in neu-
15SFL1 Occurrence condition 3 Escape procedure 1 D – L : F2 tral even when lever is
15SFMA Occurrence condition 3 Escape procedure 1 D – L : F1, R : R operated, and machine
does not move off.
15SGL1 Occurrence condition 3 Escape procedure 1 D – L : F4
15SGMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R Occurrence condition 5:
Response of lever
15SHL1 Occurrence condition 3 Escape procedure 1 D – L : F6 becomes abnormal; lever
does not work as operated
15SHMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R When lever is operated,
15SJL1 Occurrence condition 1 Escape procedure 1 D – L : F2, R : R transmission shifts to
neutral.
15SJMA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R
Normal travel possible if display Occurrence condition 6:
D1B0KZ Occurrence condition 2 Escape procedure 4 returns to normal (Note 1) Speed range remains fixed;
when the machine is
Normal travel possible if display moved off again, speed
DAQ0KK Occurrence condition 2 Escape procedure 5 returns to normal (Note 1) range does not shift.
a When lever is returned to
Normal travel possible if display N, transmission shifts to
DAQ2KK Occurrence condition 2 Escape procedure 4 returns to normal (Note 1)
neutral, but after that,
Normal travel possible if display transmission does not
DAQ9KM Occurrence condition 4 Escape procedure 9 returns to normal (Note 1) shift to any speed range.
Normal travel possible if display Note 1:

DAQ9KQ Occurrence condition 4 Escape procedure 7 returns to normal (Note 1) Even when the machine
condition is restored after a
Normal travel possible if display failure, the neutral condi-
DAQAKQ Occurrence condition 4 Escape procedure 7 returns to normal (Note 1)
tion is maintained until the
DAQSMA Occurrence condition 4 Escape procedure 1 D – L : F2, R : R lever is returned to the N
position.
DDTGKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R
Note 2:
DDTHKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R This phenomenon applies
DDTJKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R when there is no display on
the machine monitor and
DDTKKA Occurrence condition 1 Escape procedure 1 D – L : F1 there is also no display in
DDTLKA Occurrence condition 1 Escape procedure 1 D – L : F2 the display window of the
transmission controller.
DDTMKA Occurrence condition 1 Escape procedure 1 D – L : F4
DDTNKA Occurrence condition 1 Escape procedure 1 R:R
DDTPKA Occurrence condition 1 Escape procedure 1 D – L : F6
HD465-7, HD605-7 20-153

(10)
Failure Condition when failure Escape method Lever position for speed range to Remarks
code occurred move off after escape operation
Normal travel possible if display
DF10KA Occurrence condition 5 Escape procedure 8 returns to normal (Note 1) Note 1:
Even when the machine
Normal travel possible if display condition is restored after
DF10KB Occurrence condition 2 Escape procedure 8 returns to normal (Note 1)
a failure, the neutral condi-
DLE2KA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R tion is maintained until the
lever is returned to the N
DLE2LC Occurrence condition 1 Escape procedure 1 D – L : F2, R : R position.
DLF1KA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R Note 2:
DLF1LC Occurrence condition 1 Escape procedure 1 D – L : F2, R : R This phenomenon applies
when there is no display
DLF2KA Occurrence condition 1 Escape procedure 1 D – L : F1, R : R on the machine monitor
DLF2LC Occurrence condition 1 Escape procedure 1 D – L : F2, R : R and there is also no dis-
play in the display window
DLT3KA Occurrence condition 6 Escape procedure 3 D – L : F2, R : R of the transmission con-
DLT3LC Occurrence condition 6 Escape procedure 3 D – L : F2, R : R troller.
DXH1KB Occurrence condition 1 Escape procedure 1 D – L : F2, R : R
DXH2KA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R
DXH7KA Occurrence condition 3 Escape procedure 1 D – L : F4
DXH7KB Occurrence condition 3 Escape procedure 1 D – L : F1
DXHHKA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R
DXHHKB Occurrence condition 3 Escape procedure 1 D – L : F2, R : R
Normal travel possible if display
– (Note 2) Occurrence condition 2 Escape procedure 5 returns to normal (Note 1)
Escape procedure 1: Escape procedure 3:

1) Stop traveling and return the gearshift lever to 1) Stop traveling and return the gearshift lever to
the N position. the N position.
2) Operate the gearshift lever again and move the 2) Connect and disconnect emergency escape con-
machine OFF. nectors A1 (female) and A2 (male), and switch to
a When operating the gearshift lever, release the emergency escape mode.
the accelerator pedal. a Connectors A1 and A2 are installed to near
a N o D – L or N o R the fuse box.
a Connect and disconnect the connectors with
Escape procedure 2: the starting switch at ON or with the engine
Tow the machine. started.
a If the engine cannot be started and the machine 3) Operate the gearshift lever again and move the
is towed, the parking brake cannot be released machine OFF.
by operating the switch, so carry out the opera- a When operating the gearshift lever, release
tion to release it temporarily. For details, see the accelerator pedal.
METHOD FOR EMERGENCY RELEASE OF a N o D – L or N o R
PARKING BRAKE. a The emergency escape mode is maintained
until the starting switch is turned OFF.
20-154 HD465-7, HD605-7

(10)
Escape procedure 4:
Replace the transmission cut relay.
• Transmission cut relay: R15
Escape procedure 5:
Check the circuit breaker and fuse, and if they are
normal, replace the transmission controller.
• Circuit breaker: No. 23 (80A)
• Fuse: BT3-No. 14 (10A)
Escape procedure 6:
Check the fuse unit and fuse, and if they are normal,
replace the transmission controller.
• Fuse unit: Inside battery housing (30A)
• Fuse: BT2-No. 22 (10A)
Escape procedure 7:
Check the model selection setting, and if it is normal,
replace the transmission controoler.
a For details of checking the model selection set-
ting, see ADJUSTING TRANSMISSION CON-
TROLLER.
Escape procedure 8:
Check the fuse, and if it is normal, replace the gear-
shift lever.
• Fuse: BT3-No. 10 (10A)
Escape procedure 9:
Check the transmission controller harness, and if it is
normal, replace the transmission controller.
HD465-7, HD605-7 20-155

(1)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
ADJUSTING MACHINE MONITOR (EMMS)

• EMMS: Equipment Management Monitoring System
Machine monitor (EMMS) rotary switches (SW1, SW2, SW3), dipswitches (SW5, SW6), and option setting con-
nectors (OP1 – OP7)
20-156 HD465-7, HD605-7

(1)
• 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)
a 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
a 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 Spare
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.
a For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).
HD465-7, HD605-7 20-157

(10)
a All setting operations are carried out with the 1. Setting rotary switch SW1
starting switch OFF and the monitor panel Rotary switch SW1 is used to set the travel
removed. speed compensation. The machine monitor uses
a Always set each switch and connector as the size of the standard tire to calculate the travel
instructed. speed.
a Be careful not to touch anything inside the grom- If the tire size is changed, adjust the position of
met except for the switch. the switch to compensate for the speed display.
a When turning the rotary switch, use a precision a Tire size and setting position.
cross-head screwdriver and turn slowly.
a The protruding triangular part of the rotary switch Tire size SW1 Connector Remarks
is the setting arrow. HD465-7
24.0 – 35PR 7 Not needed
a When changing the dipswitch, use a precision standard tire
flat-headed screwdriver and turn slowly. a The connector in the table indicates the num-
a When setting, always avoid foreign matters or ber of the connector to be connected or
dust. released when changing the setting. (In the
a After setting, be sure to install grommet. case of SW1, there is no need to connect or
release the connector.)
a Travel speed compensation using SW1
Speed Speed
Position Position
compensation compensation
0 +7% 8 0%
1 +6% 9 –1%
2 +5% A –2%
3 +4% B –3%
4 +3% C –4%
5 +2% D –5%
6 +1% E –6%
7 0% F –7%
2. Setting rotary switch SW2

Rotary switch SW2 is used to set the maximum
speed and the maximum speed when the body is
raised.
Position of Setting of max. Setting of max. speed

SW2 speed when body is raised
0 F7 (Default) F2 (Default)
1 F5 F2
2 F4 F2
3 F6 F2
4 F5 F3
5 F4 F3
6 F6 F3
7 F5 F3
8 F4 N
9 F6 N
A F5 N
B F4 N
C
D
E
F
Connector OP3
• Setting is made: Connected
• Setting is not made: Open (Not connected)
20-158 HD465-7, HD605-7

(10)
3. Setting rotary switch SW3 7. Setting dipswitch SW5-4

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

ON Unnecessary Unit of speedometer: MPH Dipswitch SW6-4 is set as follows. The setting
must not be changed.
5. Setting dipswitch SW5-2 • Set position of dipswitch SW6-4: OFF
Use dipswitch SW5-2 to set the exhaust brake. • Connector operation: Not needed
When the exhaust brake has been installed or
removed, set as follows.
Exhaust
SW5-2 Connector OP1 Remarks
brake
Installed ON ON Connected
6. Setting dipswitch SW5-3

Dipswitch SW5-3 is set as follows. The setting
must not be changed.
• Set position of dipswitch SW5-3: OFF
• Connector operation: Not needed
HD465-7, HD605-7 20-159

(10)
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 e mark on the rotary switch is the
guideline 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.
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

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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)
PLM Card-type Set position of
VHMS function in payload Payload rotary switch 2 Date
controller VHMS meter meter (PLM) (SW2) of Time
controller function transmission 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.
a 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.
a 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.
a 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.
a Wrong setting of the model and serial No. with the VHMS initial setting tool.
5. Data cannot be downloaded.
a 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.
a Wrong setting of the date and time with the VHMS initial setting tool.
HD465-7, HD605-7 20-160-1

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SETTING OF CARD-TYPE PAYLOAD METER AFTER
TESTING AND ADJUSTING INSTALLATION OR REPLACEMENT

INSTALLATION OR REPLACEMENT
In the following cases, set the rotary switches and DIP switches on the side of the card-type payload meter and
set the threshold value of turning on the external indicator lamp and option code with the switches on the front.
• When card-type payload meter is installed for the first time

• When card-type payload meter is replaced
1. Setting of switches
1) Remove cover (1) from the left side of the card-type payload meter.
2) Set the following switches. (See view Z in the above figure.)

• Set the model selector switch (No. 4).
Position of rotary switch Model
7 HD465-7
A HD605-7
• Set weight unit setting switch (No. 7).
Position of switch Model
Upper Metric ton
Lower American ton (Short ton)
20-160-2 HD465-7, HD605-7

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• Set buzzer volume switch (No. B) and switch forcible prohibition switch (No. 8), if necessary.
When changing these switches from the initial positions, be sure to check with the Operation and
Maintenance Manual.
• Do not change the load weight correction trimmer (No. 1) from the initial position.
• Do not change the speed correction switch (No. 2), distance correction switch (No. 3), memory card
using switch (No. 5), and clinometer using switch (No. 6) from the initial positions.
Switch Initial setting
Speed correction switch (No. 2) Switch position: 7
Distance correction switch (No. 3) Switch position: 7
Memory card using switch (No. 5) Switch position: Lower (Use)
Clinometer using switch (No. 6) Switch position: Lower (Use)
Switch forcible prohibition switch (No. 8) Switch position: Upper (Permission)
a You can carry out the operations of calibration, clearing all data, dumping card, and setting date by
turning switches No. 5 and No. 8 ON or OFF. (See the Operation and Maintenance Manual.)
2. Setting of option code

a Required for communication with personal computer
The option code is set to zero (0) initially. For HD465-7 and HD605-7, check that the option code is zero by
the following method.
When the power is turned ON, "OP: 0" is indicated before the normal operation display starts.
(See Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indication.)
Optional setting
Execution of
Transmission
automatic
Option code baud rate Type of transmission of data
transmission Setting of Setting of
(bit/sec) when dumping is finished
function TALKS PMC
(when PMC is set)
0 9600 NO NO NO —
1 9600 YES NO NO —
2 1200 NO NO NO —
3 1200 YES NO NO —
4 9600 NO YES NO —
5 9600 YES YES NO —
6 1200 NO YES NO —
7 1200 YES YES NO —
8 9600 NO YES YES Z1
9 9600 NO YES YES Z2
10 9600 NO NO YES Z1
11 9600 NO NO YES Z2
HD465-7, HD605-7 20-160-3

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Method of changing option code

1) Set the gearshift lever in "N" and the dump
lever in FLOAT.
Operation switches to be used

• MODE (2)
• LIGHT/INC (3)
• TOTAL/SFT (4)
• CAL/CLR (5)
Screen (6)
a While watching the screen, operate switches
(2) – (5) to set values.
20-160-4 HD465-7, HD605-7

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2) Display the option code screen according to

Press MODE switch (2).
Press MODE switch (2) for 2 seconds. 0. XXX (0. XX lights up and X at
Display
ones place blinks)
Cd: dp (Cd lights up and dp

Display
blinks) XXX = Currently set operator ID
O
Press MODE switch (2). SP: XX (SP: X lights up and X at

Display
ones place blinks)
A. CLE (A lights up and CLE

Display
blinks) XX = Current set limit speed (km/h)
O
Press MODE switch (2). OP: XX (OP: X lights up and X at

Display
ones place blinks)
Display F. CHE (F. CHE blinks)

XX = Current set option code
d. XXX (d. XX lights up and X at

Display
ones place blinks)
XXX = Currently set machine ID
HD465-7, HD605-7 20-160-5

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3) Changing set value of option code

a You can change the digit at the blinking
place. Press LIGHT/INC switch (3).
• Changing ones digit

OP: XX (OP: X lights up and X at
Display
tens place blinks)
XX = Tens digit of currently set option code is

increased by 1.
• Changing place to be changed
a Press TOTAL/SFT switch (4).

o The blinking point moves to the ones
place.
Press LIGHT/INC switch (3).
OP: XX (OP: X lights up and X at

Display
ones place blinks)
XX = Ones digit of currently set option code is

increased by 1.
• Changing tens digit 4) Finishing setting
a Press TOTAL/SFT switch (4). a Press MODE switch (2).

o The blinking point moves to the tens
place.
20-160-6 HD465-7, HD605-7

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3. Setting threshold value of external indicator

lamp Press CAL/CLR switch (5).
a When installing the card-type payload meter
to a machine having the 3-bulb external indi-
cator lamp (HD465-7, HD605-7), be sure to PL: XX (PL: lights up and XX
Display
set the threshold value of the external indica- blinks)
tor lamp.
1) Set the gearshift lever in "N" and the dump

lever in FLOAT.
O
2) Set the threshold value of the external indi-
cator lamp according to the following proce-
dure. Press CAL/CLR switch (5).
a For the setting switches, see "2. Setting

of option code", Method of changing Display O. SEL (O. SEL lights up)
option code.
Press MODE switch (2) and LIGHT/INC

switch (3) simultaneously for 3 seconds.
O
Display CHEC (CHEC blinks)
Press CAL/CLR switch (5).
Display P. SEL (P. SEL lights up)

O
Press TOTAL/SFT switch (4) and LIGHT/INC

switch (3) simultaneously for 2 seconds.
O
Display S. SEL (S. SEL lights up)
Display H. SEL (H. SEL lights up)

O

O
UP: XX (UP: lights up and XX
Display
blinks)
Display E. SEL (E. SEL lights up)
HD465-7, HD605-7 20-160-7

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Press TOTAL/SFT switch (4). Press LIGHT/INC switch (3).
A. XXX (A. lights up and XXX c. XXX (c. lights up and XXX
Display Display
blinks) blinks)
XXX = Currently set display level of external

XXX = Set to 050.
lamp 1
O a If LIGHT/INC switch (3) is held, XXX

increases to 255 and then returns to 0.
Press CAL/CLR switch (5). O
b. XXX (b. lights up and XXX

Display
blinks) Press CAL/CLR switch (5).

d. XXX (d. lights up and XXX
lamp 2 Display
blinks)

O
lamp 4
Press CAL/CLR switch (5). O
c. XXX (c. lights up and XXX

Display
blinks) Press LIGHT/INC switch (3).

d. XXX (d. lights up and XXX
lamp 3 Display
blinks)
O XXX = Set to 090.
a If LIGHT/INC switch (3) is held, XXX

20-160-8 HD465-7, HD605-7

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4. Check of setting
For 30 seconds after the card-type payload
Press CAL/CLR switch (5). meter is turned ON, the model selection code,
setting of memory card using switch, setting of
clinometer using switch, setting of weight unit
E. XXX (E. lights up and XXX setting switch, setting of switch forcible prohibi-
Display
blinks) tion switch, and setting of option code are dis-
played. Check that they are correct.
XXX = Currently set display level of external a For contents of indication made when the
lamp 5 power is turned ON, see Operation and
Maintenance Manual, Handling of payload
meter (card type), Contents of indication.
O
Press LIGHT/INC switch (3).
E. XXX (E. lights up and XXX

Display
blinks)
XXX = Set to 105. (HD465-7)

XXX = Set to 100. (HD605-7)
a If LIGHT/INC switch (3) is held, XXX

Display CHEC (CHEC blinks)
End of setting
HD465-7, HD605-7 20-160-9

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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: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
Operator mode i
o Service mode
Service meter, odometer display Electric system fault history dis-
1 9
function (default) (*1) play function
Reverse travel distance display Mechanical system fault history
2 10
function display 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 display function
5 Language selection function
14 Snapshot function
6 PLM setup function
15 PLM setting 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

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

(10)
HD465-7, HD605-7 20-163

(2)
20-163-1 HD465-7, HD605-7

(5)
HD465-7, HD605-7 20-163-2

(5)
Operator mode
a [>], [<], [ ], [t], 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
a For selection of each function, [>], [<], [ ], [t],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.
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) t: Cancel, Release, Select (YES/NO only)
3) >: Right, Next, Continue
4) <: Left, Previous, Return
20-164 HD465-7, HD605-7

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Operation and displays for operator mode

1. Service meter, odometer display function
When the starting switch is turned ON, the top
line shows the service meter and the bottom line
shows the odometer (Fig. 1)
a For details, see STRUCTURE AND FUNC-
TION, Machine monitor system.
2. Reverse travel distance display function

Use the switch to display the total distance trav-
eled in reverse of the machine monitor (Fig. 2)
3. Filter, oil replacement interval display func-

tion
1) Filter, oil replacement time display (auto-
matic display)
When the replacement interval for the filters
or oil approaches, this information is auto-
matically displayed on the machine monitor
to recommend the operator to carry out main-
tenance (Fig. 3: example).
2) Resetting replacement time (selection menu)

When the maintenance operation for the fil-
ters and oil replacement has been complet-
ed, the switches on the machine monitor can
be used to reset the interval (Fig. 4)
a The replacement time can be set using Ser-
vice mode.
HD465-7, HD605-7 20-165

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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).
a When action code [E03] is displayed, the
telephone number is displayed at the same
time as [CALL].
a For details, see the operation manual for the
"OTHER FUNCTION OF MACHINE MONI-
TOR".
5. Language selection function

The language used for the machine monitor dis-
play can be selected by operating the switches
(Fig. 6)
a The functions of Service mode is not includ-
ed in the functions for display selection, so it
is always displayed in English.
"OTHER FUNCTION OF MACHINE MONI-
TOR".
6. PLM setting function

a This function is applied to the "PLM in
VHMS" (Only when the option is set).
• Various functions of the "PLM in VHMS" are
displayed and set (FIG. 10).
"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).
a The diagram on the right shows an example
of action code [E03] and [CALL+ Telephone
number] being displayed in turn.
a When action codes [E01] and [E02] are dis-
played, [CALL+ Telephone number] is not
displayed.
a Correspondence between action code and
recommendation to operator
20-166 HD465-7, HD605-7

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Action code CALL+ Telephone number Action recommended to operator
• Carry out testing and adjusting after completion of

E01 Not displayed operations or when changing shifts between opera-
tors
• 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
a The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are recorded
as fault history. (For details, see Service
mode.)
a If more than one failure is occurring, press
the [>] button once more to display the other
failure codes.
a 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.
a 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
a For details of the displayed failure codes, see
FAILURE CODE TABLE.
a With the failure code display function and
fault history display function (Service mode),
the data that are displayed are partially differ-
ent.
a 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

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FAILURE CODES LIST

Failure Failure phenomenon Action
Failed section Controller
code (Phenomenon/Contents of failure) code
1380MW Lockup clutch Slip (MW) TM E03
1500LO Detection of double engagement * See separate list (L0) TM E03
15B0NX Clogging of steering oil filter Clogging (NX) TM E01
15E0KM R o F gear shifting abuse 1 Mistake in operation or setting (KM) TM —
15E7KM R o 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) Lowering of oil pressure (ZG) 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

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AA10NX Air cleaner element Clogging (NX) TM E01
AB00MA Alternator Malfunction (MA) TM E03
B@BCZK Radiator coolant 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 coolant temperature sensor Out of input signal range (KX) ENG E01
C145KX Abnormality in coolant 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 coolant 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 Out of input signal range (KX) ENG E01
HD465-7, HD605-7 20-169

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C265KX Abnormality in fuel temperature sensor Out of input signal range (KX) 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 idle validation switch * See separate list (L4) ENG E01
C432L5 Idle 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 Fuel rail actuator control error * See separate list (LK) ENG E03
C514LK Fuel rail actuator defective * See separate list (LK) ENG E03
C554L6 Fuel rail pressure sensor in-range error * See separate list (L6) ENG E03
D1B0KZ Transmission 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

(10)

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 Communication defective/Abnormality in MON E01
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

(10)

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 E03
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

(10)

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 Shut-off valve Not control (K4) BK E01
DWNBKA Disconnection in shut-off valve system Not control (KA) BK E01
DWNBKB Grounding fauit in shut-off valve system Short circuit (KB) BK E01
DWNBKY Short circuit in shut-off valve system Short circuit with power line (KY) BK E01
DWNBMA Shut-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 E01
(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

(10)

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
a For details of the VHMS controller related failure codes not displayed on the machine monitor, see Trouble-
shooting VHMS control system.
a Separate table: Detailed phenomena of L Series phenomenon 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, coolant tempera-
L6
ture 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
a Failure codes with ( )

These failure codes are not recorded as fault history for either the electrical system or the mechanical sys-
tem.
a 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

(10)
Procedure for switching to Service mode and

screen display
a When using Service mode, carry out the follow-
ing special operation to switch the screen dis-
play.
1) Checking screen display

With the machine monitor in the operator mode,
check that the screen is one of the following dis-
plays: Service meter/odometer, action code, or
failure code.
2) Initial screen display for ID input

Press the following 2 buttons at the same time for
at least 5 seconds to display the initial screen dis-
play for the ID input (Fig. 1).
• [t] button and [<] button
a If the buttons are held pressed for at least 5
sec, the whole screen will give no display, so
check this condition, then release the but-
tons.
3) Inputting ID, confirming

Operate the buttons to input the ID (Fig. 2).
a ID: 6491
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes down
• [ ] button: Number at cursor is confirmed
• [t] button: Returns to initial screen (see
Note)
Note: When the cursor is at the left side, the
screen returns to the normal screen (oper-
ator mode).
If the cursor is not at the left side, the cur-
sor returns to the left side.
a If the switch on the ID input screen is not op-
erated for more than 60 seconds, the screen
returns automatically to the normal screen.
4) Displaying menu initial screen

After confirming all four digits of the ID, the menu
initial screen of Service mode is displayed (Fig.
3).
a Once the ID has been input and confirmed, it
remains effective until the starting switch is
turned OFF.
HD465-7, HD605-7 20-175

(9)
5) Menu selection in Service mode

Press the [>] or [<] buttons on the menu screen
and the menus of Service mode are displayed
endlessly in the following order (Fig. 4).
a The menu is displayed in the places marked
with [*].
• [>] button: Goes on to next menu
• [<] button: Goes back to previous menu
(1) ELECTRICAL FAULT: Fault history display
function for electrical system
(2) MACHINE FAULT: Fault history display func-
tion for mechanical system
(3) REAL-TIME MONITOR: Machine data moni-
toring function
(4) CYLINDER CUT-OUT: Reduced cylinder
mode
(5) TUNING: Adjustment function
(6) MAINTENANCE MONITOR: Filter, oil re-
placement time setting function
(7) INITIALIZE: Initialize function (exclusive
function for factory)
6) Completion of mode, function

When operating at any point in any function, it is
possible to finish the mode or function by using
any of the following methods.
(1) When continuing operations in another mode
or function:
Press the [t] button and return to the mode
screen to be used or menu screen to be
used.
a Note that if the [t] button is pressed on
the YES/NO screen, the function will be
executed.
a If you return to the normal screen (oper-
ator mode) by mistake, repeat the proce-
dure from Step 1) above (there is no
need to input the ID again).
(2) When completing all operations:
Turn the starting switch OFF.
20-176 HD465-7, HD605-7

(10)
9. Electrical system fault history 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 fault history on
the menu screen of Service mode (Fig. 1).
a The total number of fault history items re-
corded in memory is displayed in the [ ]
portion.
2) Fault history display

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

With the display function for fault history 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)
a Failure codes for problems that are still exist-
ing are shown on a flashing display.
a For details of the failure codes displayed, see
FAILURE CODE TABLE in the explanation
for the failure code display function.
a Note that with the fault history display func-
tion and failure code display function for the
electrical system, the displayed data are par-
tially different.
a If no fault history 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

(10)
4) Switching fault history display

If the [>] button or [<] button is pressed during
the display of fault history, the display switch-
es to the other recorded fault history.
• [>] button: Goes on to data for next
record number
• [<] button: Goes back to data for last
record number
5) Deleting individual fault history

i) Display the fault history to be deleted,
then press the [ ] button once to dis-
play the individual item CLEAR screen
(Fig. 4).
• [ ] button: Display CLEAR screen
ii) Operate the buttons according to the
explanation on the screen (Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
• [t] button: Run
a The data for an existing problem (flash-
ing display) cannot be deleted.
6) Deleting all fault history

i) Display the fault history, then press the
[>] button or [<] button to display the ALL
CLEAR menu (Fig. 5).
ii) Press the [ ] button once to display the
ALL CLEAR screen (Fig. 6).
• [ ] button: Run ALL CLEAR menu
iii) Operate the buttons according to the
explanation on the screen (Fig. 6).
• [t] button: Run
a The data for an existing problem (flashing
display) cannot be deleted.
20-178 HD465-7, HD605-7

(10)
10. Mechanical system fault history 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 fault history on
the menu screen of Service mode (Fig. 1).
a The total number of fault history items re-
corded in memory is displayed in the [**]
portion.
2) Fault history display

and display the fault history recorded in
memory (Fig. 2: example).
3) Displayed fault history

With the display function for fault history 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)
a Failure codes for problems that are still
existing are shown on a flashing display.
a For details of the failure codes displayed,
see FAILURE CODE TABLE in the ex-
planation for the failure code display
function.
a Note that with the fault history display
function and failure code display function
for the mechanical system, the displayed
data are partially different.
a If no fault history 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

(10)
4) Switching fault history display

If the [>] button or [<] button is pressed during
the display of fault history, the display switch-
es to the other recorded fault history.
• [>] button: Goes on to data for next
record number
• [<] button: Goes back to data for last
record number
5) Deleting fault history (not permitted)

a The fault history for the mechanical sys-
tem cannot be deleted.
20-180 HD465-7, HD605-7

(10)
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 (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).
a 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

(10)
4) Setting 1st item individual monitoring

i) Select the controller system for monitor-
ing on the sub menu screen (Fig. 4:
example).
ii) With the menu selected, press the [ ]
button and display the monitoring data
initial screen.
• [ ] button: Runs sub menu
iii) Press the [>] button or [<] button to
select the item for monitoring (Fig. 5:
example).
• [>] button: Goes on to next item
• [<] button: Goes back to last item
a Scroll the monitoring items to display in
the internally set order.
a If the button is kept pressed, the items
will scroll at high speed.
a To hold or cancel monitoring data:
If the [ ] button is pressed during monitor-
ing, the monitor data is held and the [ ] mark
flashes. If the [ ] button is pressed again, it
becomes active again.
5) Display data for 1st item individual monitor-

ing
On the 1st item individual monitoring screen,
the following data are displayed (Fig. 6).
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
a For details, see MONITORING CODE
TABLE.
20-182 HD465-7, HD605-7

(10)
6) Setting 2nd item simultaneous monitoring

i) Select the 2nd item display on the sub
menu screen (Fig. 6).
ii) With the menu selected, press the [ ]
button and display the monitoring code
input screen (Fig. 7).
• [ ] button: Runs sub menu
iii) Operate each button and input the moni-

toring code for the 2nd monitoring item
directly.
• [<] button: Number at cursor goes
down
• [ ] button: Number at cursor is con-
firmed
• [t] button: Returns to code input
screen
iv) When both of the monitoring codes have

been confirmed, the screen switches to
the 2nd item display screen (Fig. 9:
example).
a To hold or cancel monitoring data:
If the [ ] button is pressed during moni-
toring, the monitor data is held and the
[ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
7) Display data for 2nd item simultaneous mon-

itoring
On the 2nd item simultaneous monitoring
screen, the following data are displayed (Fig.
10).
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
a For details, see MONITORING CODE
TABLE.
HD465-7, HD605-7 20-183

(1)
Monitoring Code Table
MONITOR PANEL (Monitor panel system)
No. Monitoring item Item display Monitoring Display range Unit

code
1 Engine speed ENG SPEED 01001 0 – 65535 rpm
2 Engine coolant temperature (for high temperature) COOLANT TEMP 04104 0 – 160 °C
H
3 Torque converter oil temperature T/C OIL TEMP 30100 0 – 160 °C
4 Brake oil temperature BRAKE OIL 30200 0 – 160 °C

TEMP
5 Fuel level sensor input resistance value FUEL SENSOR 04201 0 – 150 z
6 Rheostat input voltage RHEOSTAT 30300 0.0 – 51.0 V
7 Operation status of front brake cut-out switch F BK CUT SW 37600 ON/OFF Status display
8 Operation status of ARSC switch ARSC SW 37700 ON/OFF Status display
9 (Operation status of ABS switch) ABS SW 37800 ON/OFF Status display
10 (Operation status of ASR switch) ASR SW 37900 ON/OFF Status display
11 Input status of connector check (1 & 2) CONN CHK 1, 2 30700 ON/OFF, ON/OFF Status display
0 – F, 0 – F,
12 Setting status of rotary switch (SW1 & SW2 & SW3) SW1, SW2, SW3 30800 0 – F,
Status display
13 Setting status of dip switch (SW5-1 & SW5-2) SW5-1, SW5-2 30900 ON/OFF, ON/OFF Status display
17 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2 31000 ON/OFF, ON/OFF Status display
a Note: The following monitoring items display data for 2 or 3 systems at the same time.
• No. 11: Input status of connector check (displays 2 items)
• No. 12: Setting status of rotary switch (displays 3 items at same time)
• No. 13: Setting status of dipswitch (displays 2 items at same time)
• No. 17: Setting status of option selection connector (displays 2 items at same time)
20-184 HD465-7, HD605-7

(10)
TRANSMISSION (Transmission controller system)

code
1 Transmission service meter SERVICE METER 31100 0 – 65535 h
2 Transmission input shaft speed T/M SPEED: IN 31200 0 – 65535 rpm
3 Transmission intermediate shaft speed T/M SPEED: MID 31300 0 – 65535 rpm
4 Transmission output shaft speed T/M SPEED: OUT 31400 0 – 65535 rpm
5 Operation status of fill switch for Lo clutch FILL SW (L) 31510 ON/OFF Status display
6 Operation status of fill switch for Hi clutch FILL SW (H) 31511 ON/OFF Status display
7 Operation status of fill switch for 1st clutch FILL SW (1st) 31512 ON/OFF Status display
8 Operation status of fill switch for 2nd clutch FILL SW (2nd) 31513 ON/OFF Status display
9 Operation status of fill switch for 3rd clutch FILL SW (3rd) 31514 ON/OFF Status display
10 Operation status of fill switch for 4th clutch FILL SW (4th) 31515 ON/OFF Status display
11 Operation status of fill switch for R clutch FILL SW (R) 31516 ON/OFF Status display
12 Operation status of fill switch for lockup clutch FILL SW (L/U) 31519 ON/OFF Status display
13 Command value of solenoid output current for Hi clutch ECMV H DIR 31600 0 – 1020 mA
14 Sensed value of solenoid output current for Hi clutch ECMV H 31610 0 – 1020 mA
15 Command value of solenoid output current for Lo clutch ECMV L DIR 31601 0 – 1020 mA
16 Sensed value of solenoid output current for Lo clutch ECMV L 31611 0 – 1020 mA
17 Command value of solenoid output current for 1st clutch ECMV 1 DIR 31602 0 – 1020 mA
18 Sensed value of solenoid output current for 1st clutch ECMV 1 31612 0 – 1020 mA
19 Command value of solenoid output current for 2nd clutch ECMV 2 DIR 31603 0 – 1020 mA
20 Sensed value of solenoid output current for 2nd clutch ECMV 2 31613 0 – 1020 mA
21 Command value of solenoid output current for 3rd clutch ECMV 3 DIR 31604 0 – 1020 mA
22 Sensed value of solenoid output current for 3rd clutch ECMV 3 31614 0 – 1020 mA
23 Command value of solenoid output current for 4th clutch ECMV 4 DIR 31605 0 – 1020 mA
24 Sensed value of solenoid output current for 4th clutch ECMV 4 31615 0 – 1020 mA
25 Command value of solenoid output current for R clutch ECMV R DIR 31606 0 – 1020 mA
26 Sensed value of solenoid output current for R clutch ECMV R 31616 0 – 1020 mA
27 Command
clutch
value of solenoid output current for lockup
ECMV LU DIR 31609 0 – 1020 mA
28 Sensed value of solenoid output current for lockup clutch ECMV LU 31619 0 – 1020 mA
29 Fill time of Hi clutch FILL TIME H 41801 0 – 2550 ms
30 Fill time of Lo clutch FILL TIME L 41800 0 – 2550 ms
31 Fill time of R clutch FILL TIME R 41806 0 – 2550 ms
32 Fill time of 1st clutch FILL TIME 1 41802 0 – 2550 ms
HD465-7, HD605-7 20-185

(10)

code
33 Fill time of 2nd clutch FILL TIME 2 41803 0 – 2550 ms
34 Fill time of 3rd clutch FILL TIME 3 41804 0 – 2550 ms
35 Fill time of 4th clutch FILL TIME 4 41805 0 – 2550 ms
36 Fill status of Hi clutch FILL H 31501 0–2 Status display
37 Fill status of Lo clutch FILL L 31500 0–2 Status display
38 Fill status of R clutch FILL R 31506 0–2 Status display
39 Fill status of 1st clutch FILL 1 31502 0–2 Status display
40 Fill status of 2nd clutch FILL 2 31503 0–2 Status display
41 Fill status of 3rd clutch FILL 3 31504 0–2 Status display
42 Fill status of 4th clutch FILL 4 31505 0–2 Status display
43 Input voltage of acceleration sensor THROTTLE POS 31700 0.00 – 5.10 V
44 Operation status of emergency steering (1 & 2) ENERG STRG 1,2 32100 ON/OFF, ON/OFF Status display
45 Input status of alternator terminal R ALTERNATOR R 04301 ON/OFF Status display
46 Input status of starting switch terminal C KEY SW C 32300 ON/OFF Status display
47 Setting status of emergency escape switch ENERG TRAVEL 32400 ON/OFF Status display
48 ECMV oil temperature ECMV OIL TEMP 32500 0 – 160 °C
49 Torque converter oil pressure T/C OIL PRESS 32600 0.00 – 5.02 MPa
OVERHEAT/NOR-
50 Steering oil temperature STRG OIL TEMP 32700 MAL Status display
51 Output status of overrun prevention brake OVERRUN BK DIR 35001 ON/OFF Status display
52 Output status of DROOP MODE 2 (P/E) DROOP MODE 2 38100 ON/OFF Status display
53 Connector check input status (1 & 2) CONN CHK 1,2 30701 ON/OFF, ON/OFF Status display
54 Hydraulic tank level HYD OIL LEVEL 33000 LOW/NORMAL Status display
55 Engine oil tank level ENG OIL LEVEL 38200 LOW/NORMAL Status display
56 Transmission oil tank level TM OIL LEVEL 38300 LOW/NORMAL Status display
57 Electrolyte level BATT LIQ LEVEL 40302 LOW/NORMAL Status display
58 Radiator coolant level COOLANT LEVEL 33100 LOW/NORMAL Status display
59 Clogging status of air cleaner CLOGGED/NOR- Status display

AIR CLEANER 33200 MAL
CLOGGED/NOR-
60 Clogging status of transmission filter T/M FILTER 33300 MAL
Status display
CLOGGED/NOR- Status display
61 Clogging status of hydraulic oil filter HYD OIL FILTER 33400 MAL
62 Clogging status of engine oil filter CLOGGED/NOR- Status display

ENG OIL FILTER 38400 MAL
63 Judgment of acceleration at gear shifting point ACCELERATON 38500 QUICK/NRMAL Status display
64 Holding status of skip-shift TM SKIP SHIFT 38600 KEEP/NORMAL Status display
65 Gear shift mode status TM SHIFT MODE 38700 0–F Status display
20-186 HD465-7, HD605-7

(10)

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

(10)
ENGINE (Engine controller system)

code
1 Engine speed ENG SPEED 01002 0 – 8032 rpm
2 Opening rate of acceleration sensor THROTTLE POS 31701 0.0 – 100 %
3 Fuel temperature FUEL TEMP 04203 -40 – 210 °C
4 Fuel (rail) pressure METRING PRESS 37000 0.00 – 9.99 MPa
5 Fuel consumption FUEL RATE 37300 0.0 – 999.9 L/h
6 Timing rail pressure TIMING PRESS 37100 0.00 – 9.99 MPa
7 Boost pressure BOOST PRESS 36500 0 – 300 kPa
8 Engine coolant temperature COOLANT TEMP 04104 -40 – 210 °C
9 Engine oil pressure ENG OIL PRESS 37200 0 – 1000 kPa
10 Temperature in intake manifold AIR TEMP 37500 -273.0 – 1735.0 °C
11 Atmospheric pressure AIR PRESS 37400 0.0 – 125.0 kPa
20-188 HD465-7, HD605-7

(10)
BRAKE (Retarder controller system)

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 Inclination angle switch INCLINATION SW 39000 ON/OFF Status display
23 Command of front brake cut FBK CUT DIR 39100 ON/OFF Status display
24 Hoist lower pressure HOIST PRESS 34501 0.00 – 50.26 MPa
25 Auto suspension mode AUTO SUS MODE 39200 MEDIUM/SOFT/ Status display
HARD
26 Auto suspension solenoid 1 output AUTO SUS DIR 1 39300 ON/OFF Status display
27 Auto suspension solenoid 2 output AUTO SUS DIR 2 39301 ON/OFF Status display
28 Front suspension pressure (right) SUS PRESS (FR) 32802 0.00 – 20.10 MPa
29 Front suspension pressure (left) SUS PRESS (FL) 32803 0.00 – 20.10 MPa
30 Judgment of load EMPTY OR LOAD 39400 EMPTY/LOAD Status display
31 Accelerator sensor THROTTLE POS 31704 0.00 – 3.10 V
32 Travel speed set with ARSC switch ARSC SET SP SW 37701 0.00 – 3.10 V
HD465-7, HD605-7 20-189

(10)
BRAKE [Retarder controller system]

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

SPEED
44 Wheel speed (RL) WHEEL SPEED 39700 0.0 – 65535 rpm
RL
45 Wheel speed (RR) WHEEL SPEED 39701 0.0 – 65535 rpm
RR [0000 – FFFF]
XXXXRYYY
part No. from left
are displayed]
46 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
part No. from left
are displayed]
47 Part No. of software (For sub-CPU) BRAKE ROM 2 20207 Example: If part Status display
No. is 7831-46-
R110, 3146R110 is
displayed.
a Note: The following monitoring items display data for 2 systems at the same time.
• No. 4: Retarder lever input (displays 2 types at same time; does not display unit for conversion %)
• No. 5: Input status of retarder lever validation switch (displays 2 systems at same time)
• No. 18: Connector check input status (displays 2 systems at same time)
20-190 HD465-7, HD605-7

(10)
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
– – – – (*)
a 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

(10)
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 tem-
code in the chart on the right) DGF1KA
perature 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).
a ( ) 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)
a 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

(5)
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.
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 idle 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

(9)
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 idle
• 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

(10)
Adjustment operation (2): Resetting gearshifting

feeling stabilized learning data
1) Operate the machine monitor and display the ini-
tial menu screen (Fig. 7).
• Initial menu: 01: TM TRIGGER
a The present initial status is displayed on the
bottom line of the screen.
• Initializing completed: INITIAL STATUS
• Initializing not performed: TUNED
a With the transmission adjustment, the learn-
ing data is initialized from the following oper-
ation, regardless of the present initial status.
2) With the menu selected, press the [ ] button

and display the initial screen of the sub menu
(Fig. 7).
• [ ] button: Runs initialize menu
3) Operate the buttons according to the screen dis-

play (Fig. 8).
• [t] button: Run
a After carrying out initializing, check that INI-
TIAL STATUS is displayed on the bottom line
of the screen.
20-194 HD465-7, HD605-7

(1)
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.
a 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 idle and hold the gearshift
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

(10)
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
(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
a The presently set interval is dis-
played on the screen.
20-196 HD465-7, HD605-7

(9)
i) Operate the buttons to input the interval

(Fig. 4).
• [<] button: Number at cursor goes
down
• [ ] button: Number at cursor is con-
firmed
• [t] button: Returns to item selection
screen
a The time must always be input with
four digits. For numbers of less than
four digits, input 0s at the beginning.
ii) When all the interval times are con-
firmed, the change confirmation screen
is displayed, so operate the buttons
according to the screen display (Fig. 5).
• [t] button: Run
Table of filter and oil replacement time set items
No. Item Code Display Replacement time

1 Fuel filter 03 FUEL FILT 0500
2 Engine oil filter 02 ENG FILT 0500
3 Engine oil 01 ENG OIL 0500
4 Transmission oil filter 13 TM FILT 0500
5 Corrosion resistor 06 CORR RES 1000
6 Torque convertor, transmission, brake oil 24 TC/TM/BK OIL 1000
7 Brake oil filter 14 BK OIL FIL 1000
8 Brake cooling oil filter 16 BK C FIL 1000
9 Hydraulic filter 04 HYD FILT 2000
10 Differential case oil 11 DIFF OIL 2000
11 Final drive oil 08 FNL OIL 2000
12 Hydraulic oil 10 HYD OIL 4000
HD465-7, HD605-7 20-197

(1)
14. Snap shot function

a For this function, see "Execution of PM clinic
using manual snap shot (Another name:
Quick PM)" (Drawing No. WJ021D060) (Fig.
1).
15. PLM setting function

a This function is applied to "PLM having
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.
• [t] button: Stop inputting number.
a The setting range is 0 – 255 m (0.0 –
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 travel distance for this
purpose.
20-197-1 HD465-7, HD605-7

(10)
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-
ous screen.
a 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 (See Fig. 11).
• Check the unit of the input
value.
a The unit is indicated in the ( )
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
been completed.
a Display on the screen (Fig. 5)
• [U] button: Check that measure-
ment has been completed and
go to the next step.
ous screen.
HD465-7, HD605-7 20-197-2

(5)
(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-
ous screen appears.
a Inputtable range
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
start driving the dump truck.
a Drive the dump truck for about 3
minutes (at a speed higher than
8 km/h) to enter the relationship
between the weight of the dump
truck and the suspension pres-
sure under that weight.
• [t] button: Return to the screen
for inputting values.
20-197-3 HD465-7, HD605-7

(5)
(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
screen.
a As measurement is executed,
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
screen.
a When loading is started, the menu
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"
temporarily and return to "Display of
load/integrated odometer". On this
screen, you can check the current
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.
11).
a For the method of displaying the
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
screen.
a 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 (See Fig. 11).
• Check the unit of the input
value.
a The unit is indicated in the ( )
on the right side of WEIGHT.
HD465-7, HD605-7 20-197-4

(9)
(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-
ous screen appears.
a Inputtable range
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

(5)
(5) Move the dump truck to a place

where you can drive it.
• [U] button: After getting ready
for drive, press this button and
start driving the dump truck.
a Drive the dump truck for about 3
minutes (at a speed higher than
8 km/h) to enter the relationship
between the weight of the dump
truck and the suspension 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
screen.
a As measurement is executed,
the number of " * " increases.
When measurement is finished,
the next screen appears auto-
matically.
vi) Dump the load in the dump area (Fig.
12).
screen.
a If the load is dumped with the dump
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.
screen.
a The current standard level value
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

(5)
(2) Turn the dump truck 180 degrees

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

(5)
• 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
the previous menu screen (Fig. 21).
a The unit is indicated in the ( ) on
the right side of the input value
[t].
HD465-7, HD605-7 20-197-8

(5)
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)
a This is a special function for the factory and
is not used for service.
20-198 HD465-7, HD605-7

(5)
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 i) 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

(10)
ii) When installing battery isolator or other

battery shut-down device
a) Basic connections
It is a basic assumption that the
engine stop switch is a type that will
not shut off the permanent power
source when the engine is stopped.
b) When safety regulations for user
make it impossible to avoid shutting
down all electric power
• Install a battery isolator so that
the permanent power source is
kept in the specified condition for
at least 3 minutes after the 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
i) Download VHMS data ii) Specified method of shutting down
When the VHMS controller is replaced, VHMS power source
the data collected up to that point is lost, a) Use the starting switch to turn the
so be sure to download the accumulated normal power source OFF
data before starting the replacement b) Maintain the permanent power
operation. source in the specified condition for
Next, send the accumulated data to web at least 3 minutes.
care. c) 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

(10)
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

(2)
TESTING AND ADJUSTING OUTLINE
OUTLINE
a 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

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

(2)
HD465-7, HD605-7 20-203-6

(2)
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

(2)
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

(2)
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 (date, 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

(12)
TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER
4. Checking operation, actuation

a 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
a 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

(2)
TESTING AND ADJUSTING COLLECTION, TRANSMISSION OF DATA
COLLECTION, TRANSMISSION OF DATA

1. Collection of data
1) Downloading with PC (personal computer) a 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

a 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 idle, 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 level
ground and put chocks 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.
a 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.
a The download connectors are provided in 2
places: rear of assistant's seat inside cab (7) and
behind front left tire of machine (6).
20-203-11 HD465-7, HD605-7

(10)
<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
a 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 (if equipped) : This records the payload meter data
15) Payload data cycle (if equipped) : This records the operating cycle data for the machine
HD465-7, HD605-7 20-203-12

(10)
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.) mmAq (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 idle (min.) kg/cm2 Engine controller
9 E. oil P. H min. Engine oil pressure at high idle (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
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(n361)
No. 4,5,6 cylinder exhaust temperature is high 12 Problem with No. 3 clutch 15M0MW(b026)
2 (stage 1) F@BZNS(n371)
3 Blow-by pressure is high F@BBZL(n338) 13 Problem with No. 4 clutch 15N0MW(b027)

No. 1,2,3 cylinder exhaust temperature is high 14 Problem with engine speed senser C115KZ
4 (stage 2) F@BYNR(n362)
No. 4,5,6 cylinder exhaust temperature is high 15 Overheating of water C151NS
5 (stage 2) F@BZNR(n372)
6 Double meshing of transmission clutch 1500L0(b005) 16 Overheating of fuel 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(n201)
10 Problem with No. 1 clutch 15K0MW(b024) 20 Abnormal drop in engine oil pressure C143ZG
20-203-13 HD465-7, HD605-7

(12)
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
4 Blow-by press. Blow-by pressure mmAq Crankcase internal

pressure sensor
Exhaust temperature (No. 1,2,3 cylin- Exhaust temperature
5 F. exh. temp. deg. C sensor
ders)
Exhaust temperature (No. 4,5,6 cylin- Exhaust temperature
6 R. exh. temp. deg. C
ders) sensor
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
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 (fill time) Transmission fill-up time msec. Transmission controller (Every 200 h)
Trig. time 3rd
(fill time)
Trig. time 1st
(fill time)
Trig. time 2nd
(fill time)
HD465-7, HD605-7 20-203-14

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5. Confirming data <Checking quick PM data>

For details of the method of confirming the data, • Engine speed (high idle, torque converter stall)
see the instruction manual for the technical anal- • Blow-by pressure (high idle, torque converter
ysis tool box. stall)
a Check that each file has been saved. Check • Exhaust temperature (torque converter stall)
also that there is no abnormal data. • Engine oil pressure (low idle, high idle, torque
a 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)
a 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

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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
a 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

(2)
TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS
PROCEDURE FOR INITIAL SETUP OF VHMS

(Applicable machine models: HD465/605-7 Dump Truck)
Timing Operation step Operation step
* There are download connectors in two places (inside cabin, ground level
download box), but the setting operation must be carried out inside the cab.
Before starting • Prepare necessary parts, tools, and check sheet. 799-608-3220 Download cable
operation • Contact Komatsu before starting the setup 799-608-3211 Program for setting(VHMS technical analysis tool box)
operation. (Contact at least 3 days before) Portable PC
Check the serial No. first from the following nameplates

1. Check machine and component and enter the serial No. on the check sheet.
nameplates • Machine • Engine • Transmission
• VHMS controller
Starting switch OFF Connect the cable (799-608-3220) to the VHMS

2. Connect PC and VHMS controller controller download connector (VHMS).
Connect the other end to the RS232C port of the
portable PC.
Starting switch ON Check the 7-segment display window of the VHMS controller to see that the LED operation is normal.
3. Check that VHMS controller works * With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes
properly in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.
Do not start
engine yet. Start up the personal computer and click the VHMS initial setup tool icon.
4. Start VHMS initial setup tool For details of the method of installing the VHMS initial setup Icon
(VHMS technical tool box) program, see the separate program operation instructions.
(automatic updating of definition data) If the definition data for the connected machine is not in the
technical analysis tool box on the personal computer,
download automatically from the VHMS controller and update
the technical analysis tool box. Press the YES button to update.
Note: This program

5. Initial setup of VHMS controller will not start if the
VHMS controller
and PC are not
After starting up, first input the ID (Service ID). connected.
Select "Data Clear and Set up".
The ID is the part No. for the VHMS
controller. It differs according to the
5-1 Setting up machine data machine model.
This sets the basic data for the 1) Setting calendar

machine in the VHMS controller. • Set the present time and date.
2) Confirming machine model and setting
serial No.
• After checking the machine model, set
the machine serial No.
3) Setting of variation code
Select and set by clicking (See the
attached table).
4) Setting engine Serial No.
5) Setting transmission Serial No.
• Set the transmission Serial No. in engine
Serial No. 2.
Finally, click OK.
Click Apply to register the setting
Starting switch OFF Check the 7-segment display in the VHMS controller inspection window.
6. 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.
Starting switch ON
** When using the payload meter as shipped (default), (Default setting)
the following setting is not necessary ** • Time when collection is started: 12 o'clock (Midnight)
• Unit of collection (Day) : 1 day
7. Setting of payload meter
7-1 Check of operation of VHMS Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller.
controller * The normal operation of the LED means that the 7 segments flash in the rotation state after the
starting switch is turned to the ON position and then they count up in hexadecimal notation.
For details, see the Shop Manual.
7-2 Starting of VHMS initial setting Start the personal computer and click the icon of "VHMS initial setting tool".
tool
For the method of installing the program for setting the VHMS initially,
Icon see the separate operation manual for the program.
If the definition information of the connected machine is not in

"Analysis tool" of the personal computer, it is downloaded
automatically from the VHMS controller and
"Analysis tool" is updated. Note: This program
Press the "yes" button to update. will not start if the
VHMS controller
After the personal computer starts, input
and PC are not
the ID (Service ID) first. connected.
Select "Set up".
The ID is the part No. for the VHMS

controller. It differs according to the
machine model.
(Cont'd) (Cont'd)
20-203-17 HD465-7, HD605-7

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7-3 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.
8. 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
9. 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]

10. 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
11. 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.
12. 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
13. 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 [8] are saved in "Snap Shot".
14. 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.
[1] Send the check sheet by fax.
[2] Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS/WebCARE Support Center

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)
Welcome to WebCARE TEL: 81-3-5561-2765
Use WebCARE to check the data FAX: 81-3-5561-4766
https://wcare.komatsu.co.jp E-mail: [email protected]
Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM
controller
Set position of Setting with VHMS initial setting manual (tool) (*1)
PLM Card-type
VHMS function in Payload meter rotary switch 2 Date
payload meter (SW2) of Set Time
controller VHMS (PLM) function Model Type variation Time difference
controller (PLM- ) transmission
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
Set
Installed Not installed Installed Installed F or –7 P2
HD605 properly
Installed Installed Not installed Installed 9 PV
a 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)".
a 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 2 (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

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To: VHMS/WebCARE Support Center Date of setup Month Day Year

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD) Date of fax Month Day Year
Name of
FAX: 81-3-5561-4766 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
1. Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
2. Connect PC and VHMS controller Are they are properly connected? yes no
3. Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, hexadecimal count-up display)
4. Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up" ?
5. Initial setup of VHMS controller Is model name same as name of machine? yes no
5–1 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
6. Save settings After saving operation, did LED (7 segments) go off? yes no
7. Setting of payload meter

7–1 Check of operation of VHMS controller Did LED operate normally? yes no
7–2 Starting of VHMS initial setting tool Is selection of mode of setting tool
yes no
"Set up"?
7–3 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
9. Check of normal operation of VHMS Did LED operate normally? yes no

controller
10. Perform quick PM clinic Were service mode and "SNAPSHOT" selected and
yes no
was switch pressed?
11. Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
12. Download Did LED operate normally? yes no
13. 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
14. Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
Point of Contact VHMS/WebCARE Support Center

TEL: 81-3-5561-2765
FAX: 81-3-5561-4766
E-mail: [email protected]
20-203-19 HD465-7, HD605-7

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TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE
PROCEDURE FOR OPENING ORBCOMM SERVICE

(Applicable machine models: HD465/605-7 Dump Truck)
a Make a communications contract with Orbcomm before performing this work.
* There are download connectors at two places (inside cabin, ground level
download box), but the setup operation must be carried out inside the cab.
Before starting • Prepare the necessary tools and check sheet. 799-608-3220 Download cable
operation • Contact Komatsu before starting the setup 799-608-3211 VHMS technical analysis tool box
operation. (Contact at least 3 days before) Portable PC
Check the serial No. first from the following nameplates

1. Check machine and component and enter the serial No. on the check sheet.
nameplates • Machine • Engine • Transmission
• VHMS controller • Orbcomm controller
Starting switch OFF Connect the cable (799-608-3220) to the VHMS

2. Connect PC and VHMS controller controller download connector (VHMS).
Connect the other end to the RS232C port of the
portable PC.
Starting switch ON Check the 7-segment display window of the VHMS controller to see that the LED operation is normal.
3. Check that VHMS controller works * With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment
properly flashes in a rotating movement, then displays the hexadecimal count-up. For details, see the
shop manual.
(Check that the Orbcomm controller When checking that the operation of the Orbcomm controller is normal, wait for 3 minutes after
works properly) starting the VHMS, then check the condition of the decimal point on the VHMS monitor (7-segment).
(When an Orbcomm controller • OFF : ORBCOMM controller cannot communicate with ORBCOMM terminal.
is installed) • ON : Communication with ORBCOMM terminal is OK.
Terminal does not have communication data.
• Quick flash : Communication with ORBCOMM terminal is OK.
Terminal has communication data and has captured satellite.
• Slow flash : Communication with ORBCOMM terminal is OK.
Terminal has communication data and has not captured satellite.
Start up the personal computer and click the VHMS initial setup tool icon.
4. Start VHMS initial setup tool Icon
(VHMS technical tool box) For details of the method of installing the VHMS initial
setup program, see the separate program operation
(automatic updating of definition data) instructions.
If the definition data for the connected machine is not in the
technical analysis tool box on the personal computer,
download automatically from the VHMS controller and update the technical analysis tool box.
Press the YES button to update.
Note: This
5. Initial setup of VHMS controller After starting, input the ID (Service ID) first.
program will not
Select "Set up". start if the VHMS
The ID is the part No. for the controller and
VHMS controller. It differs PC are not
according to the machine model. connected.
5-1 Setting up communications 1) Selecting data to send

(For machines with Orbcomm – – There are 3 types of data that can be sent. With this operation is possible to set
controller specifications) acceptance /refusal of satellite communications and the frequency of change.
This sets up the selection of VHMS – – Decide the data to change, then click on
data to be sent by satellite communications Edit to change it.
*
and the frequency of communications.
*1: The default for the

number of items in the
* (The setting of the machine data Fault History is 8.
and PLM is already completed) For details, see the
instruction manual for the
setup tool.
5-2 Set start of communications

2) Setting up GCC code Territory
GCC code
– – Click Edit and select 130 (if Japan) for the (country)
GCC code. 1 USA
120 ITALY
121 MALAYSIA
Finally, click Apply to register the setting. 122 KOREA
123 BRAZIL
(Cont'd) 130 JAPAN
HD465-7, HD605-7 20-203-20

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Starting switch OFF 6. 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.
1) Send the check sheet by fax.
2) Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS/WebCARE Support Center

Welcome to WebCARE TEL: 81-3-5561-2765
Use WebCARE to check the data FAX: 81-3-5561-4766
https://wcare.komatsu.co.jp E-mail: [email protected]
20-203-21 HD465-7, HD605-7

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To: VHMS/WebCARE Support Center Date of setup Month Day Year

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD) Date of fax Month Day Year
Name of
FAX: 81-3-5561-4766 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
1. Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Orbcomm controller serial No.
2. Connect PC and VHMS controller Are they are properly connected? yes no
3. 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)
4. Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up"?
5. Initial setup of VHMS controller
5–1 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
5–2 Set start of communications Is GCC code set to 130 (if Japan) yes no
Point of Contact VHMS/WebCARE Support Center

TEL: 81-3-5561-2765
FAX: 81-3-5561-4766
E-mail: [email protected]
HD465-7, HD605-7 20-203-22

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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 level

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

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

(10)
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 idle and stabilize it for 2

minutes.
a Check that the coolant temperature gauge
and torque converter oil temperature gauge
are in the white range.
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 idle (Low) Auto Economy N ON ON Hold
2 2 : 00 3 : 00 60 sec Low idle (Hi) Auto Economy N OFF OFF Hold (*1)
3 3 : 00 4 : 00 60 sec High idle (Stationary mode) Auto Economy N ON ON Float
4 4 : 00 5 : 00 60 sec Low idle (Hi) Auto Economy N ON ON Hold
5 5 : 00 5 : 30 30 sec High idle (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 idle (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 idle (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 idle temporarily (to prevent the
machine from running out).
HD465-7, HD605-7 20-204-1

(10)
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.
a 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

(2)
• 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 Lubricating oil Exhaust pressure
speed pressure pressure temperature (*1)
1 Low idle Low
2 Low idle High
3 High idle Stationary mode
4 Low idle Economy mode
5 High idle Economy mode
Torque converter
6 stall Economy mode
7 High idle Power mode
Torque converter
8 stall Power mode
High idle
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

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

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20-206 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-207

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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 ASR controller system (ASR mode) ........................................................................... 20-1051
Troubleshooting of hydraulic and mechanical systems (H mode) .............................................................20-1101
Troubleshooting of engine system (S mode) ............................................................................................20-1151
Troubleshooting of electrical system (E mode) ........................................................................................ 20-1201
Troubleshooting of ABS controller system (ABS mode) (If equipped) ...................................................... 20-1251
HD465-7, HD605-7 20-301

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TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level ground, and check that the safety pin, chocks, and parking brake are securely fitted.
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 hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
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 the 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 hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. W hen operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that ma y
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma - 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 HD465-7, HD605-7

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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

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TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric equip-

ment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one
component to another component, connectors used
for connecting and disconnecting one wire from
another wire, and protectors or tubes used for protect-
ing the wiring.
Compared with other electrical components fitted in
boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection and repair
operations, they are frequently removed and installed
again, so they are likely to suffer deformation or dam-
age. For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
Main failures occurring in wiring harness

• Defective contact of connectors (defective contact
between male and female)
Problems with defective contact are likely to occur
because the male connector is not properly inserted
into the female connector, or because one or both of
the connectors is deformed or the position is not cor-
rectly aligned, or because there is corrosion or oxi-
dization of the contact surfaces.
• Defective crimping or soldering of connectors

The pins of the male and female connectors are in
contact at the crimped terminal or soldered portion,
but if there is excessive force brought to bear on the
wiring, the plating at the joint will peel and cause
improper connection or breakage.
20-304 HD465-7, HD605-7

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• Disconnections in wiring
If the wiring is held and the connectors are pulled
apart, or components are lifted with a crane with the
wiring still connected, or a heavy object hits the wiring,
the crimping of the connector may separate, or the
soldering may be damaged, or the wiring may be bro-
ken.
• High-pressure water entering connector

The connector is designed to make it difficult for water
to enter (drip-proof structure), but if high-pressure
water is sprayed directly on the connector, water may
enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed to prevent
water from entering, but at the same time, if water
does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropri-
ate action before passing electricity through it.
• Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil
film is formed on the mating surface between the male
and female pins, the oil will not let the electricity pass,
so there will be defective contact.
If there is oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air
and spray it with a contact restorer.
a When wiping the mating portion of the connector,
be careful not to use excessive force or deform
the pins.
a If there is oil or water in the compressed air, the
contacts will become even dirtier, so remove the
oil and water from the compressed air completely
before cleaning with compressed air.
HD465-7, HD605-7 20-305

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2) Removing, installing, and drying connectors and

wiring harnesses
i) Disconnecting connectors
a) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the con-
nectors and not the wires. For connectors held by
a screw, loosen the screw fully, then hold the male
and female connectors in each hand and pull
apart. For connectors which have a lock stopper,
press down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
b) When removing from clips

When removing a connector from a clip, pull the
connector in a parallel direction to the clip.
a If the connector is twisted up and down or to
the left or right, the housing may break.
c) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from get-
ting in the connector portion.
a If the machine is left disassembled for a long
time, it is particularly easy for improper contact
to occur, so always cover the connector.
20-306 HD465-7, HD605-7

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ii) Connecting connectors

a) Check the connector visually.
• Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
• Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
• Check that there is no damage or breakage to
the outside of the connector.
a If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm the
inside of the wiring with a dryer, but be careful
not to make it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace
the connector.
b) Fix the connector securely.

Align the position of the connector correctly, then
insert it securely.
For connectors with lock stopper, push in the con-
nector until the stopper clicks into position.
c) Correct any protrusion of the boot and any mis-

alignment of the wiring harness
For connectors fitted with boots, correct any pro-
trusion of the boot. In addition, if the wiring har-
ness is misaligned, or the clamp is out of position,
adjust it to its correct position.
a If the connector cannot be corrected easily,
remove the clamp and adjust the position.
d) If the connector clamp has been removed, be sure

to return it to its original position. Check also that
there are no loose clamps.
HD465-7, HD605-7 20-307

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iii) Connecting DT connectors

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.
Male connector (1). Female conector (2).
Normal locking state (Horizontal): a, b, d

Incomplete locking state (Diagonal): c
iv) 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.

a) Disconnect the connector and wipe off the water
with a dry cloth.
a 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.
b) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
a 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.
c) 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.
a After completely drying the connector, blow it
with contact restorer and reassemble.
20-308 HD465-7, HD605-7

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3) Handling control box

i) The control box contains a microcomputer and
electronic control circuits. These control all of the
electronic circuits on the machine, so be
extremely careful when handling the control box.
ii) Do not open the cover of the control box unless
necessary.
iii) Do not place objects on top of the control box.

iv) Cover the control connectors with tape or a vinyl
bag.
Never touch the connector contacts with your
hand.
v) During rainy weather, do not leave the control box
in a place where it is exposed to rain.
vi) Do not place the control box on oil, water, or soil,

or in any hot place, even for a short time.
(Place it on a suitable dry stand).
vii) Precautions when carrying out arc welding
When carrying out arc welding on the body, dis-
connect all wiring harness connectors connected
to the control box. Fit an arc welding ground close
to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
HD465-7, HD605-7 20-309

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3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic

equipment, the most common cause of failure is dirt (for-
eign material) in the hydraulic circuit. When adding
hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly
careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repair-
ing the machine in rain or high winds, or places where
there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of
dust entering the equipment. It is also difficult to con-
firm the performance after repairs, so it is desirable to
use unit exchange. Disassembly and main-tenance of
hydraulic equipment should be carried out in a specially
prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the open-
ings should be sealed with caps, tapes, or vinyl bags
to prevent any dirt or dust from entering. If the open-
ing is left open or is blocked with a rag, there is dan-
ger of dirt entering or of the surrounding area being
made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground, collect it
and ask the customer to dispose of it, or take it back
with you for disposal.
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when refill-
ing with hydraulic oil. Always keep the oil filler and the
area around it clean, and also use clean pumps and
oil containers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collected during
storage, so this is an even more effective method.
20-310 HD465-7, HD605-7

(1)
5) Change hydraulic oil when the temperature is

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

(1)
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 Add oil
4. Check oil level in hydraulic tank Sight gauge Add oil
5. Check oil level in engine oil pan Oil level gauge Add oil
6. Check coolant level — Add coolant
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

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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 — Dry
connectors and terminals)
38. Check for blown fuses, defective contact — Replace
39. Check alternator voltage after several minutes of run-
ning (engine at 1/2 throttle or above) 27.5 – 29.5 V Replace
40. Check for actuation sound from battery relay (when — Replace
starting switch is turned ON-OFF)
HD465-7, HD605-7 20-312-1

(10)
CATEGORIES, PROCEDURE, AND METHOD OF
TROUBLESHOOTING USING TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING TROU-

BLESHOOTING CHARTS
1. Category of troubleshooting code
a 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 controller name. (This may also include the
electrical system, where some failure codes are not displayed).
a 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
S Troubleshooting of engine body
E Troubleshooting of electrical system
2. Troubleshooting procedure
a 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 fault history is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the fault
history 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 fault history 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 fault history 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

(11)
Phenomena considered to be failures and troubleshooting No.

q go to troubleshooting No. on failure code display
Troubleshooting
No. Phenomena considered to be failures
Error ENG TM BK LC MON VHMS H S
code mode mode mode mode mode mode mode mode
Error code related
1 Error code is displayed in error code display mode q

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 coolant, or water spurts back, or coolant level S-11

goes down
15 Oil pressure caution lamp lights up S-12
(drop in oil pressure)
16 Oil level rises S-13
17 Coolant 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 pre-
20
heating Engine is still preheated after pre- ENG-2b)
heating 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 TM-2b)
(Backup buzzer is normal)
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

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Troubleshooting
Retarder controller related
When the parking brake switch is
set in the OFF position, the park- BK-1a)
Parking brake ing brake s not released
28 does not oper-
ate normally When the parking brake switch is
set in the PARK position, the park- BK-1b)
ing brake does not work
29 Retarder brake oil temperature gauge does not oper- BK-2
ate normally
Inclination alarm is turned ON when dump body is
30 raised BK-3
(When chassis is not inclined laterally more than 15°)
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 dis- LC-1
played
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
Cycle data and engine ON/OFF data not recorded
36 (charge level signal system: judges that engine is LC-5
stopped)
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 trav-
39 eling, display of odometer does LC-7b)
not increase
Displayed logic When travel speed exceeds limit
40 is abnormal speed, "SP:SP" does not go off LC-7c)
41 Integrated pay load is not dis- LC-7d)

played
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 mem- LC-10
ory is full)
46 Payload meter displays "F-20" :failure in power source LC-11
of suspension pressure sensor and clinometer system
Payload meter displays "F-21" – "F-24" : disconnection
47 or grounding fault in suspension pressure sensor signal LC-12
system
48 Payload meter displays "F-25" – "F-28" : short circuit LC-13
with power source in suspension sensor signal system
Payload meter displays "F-CAL"
49 (negligence of calibration or internal damage of pay- LC-14
load meter)
Payload meter displays "F:43" – "F:45"
50 (short circuit with power source in external pilot lamp relay LC-15
system)
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 dis- LC-18
connection 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

(10)
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- MON-2
itor does not operate normally
Alarm buzzer does not sound MON-3a)
58 Alarm buzzer
defective Alarm buzzer does not stop sound-
ing MON-3b)
Items displayed by gauges are dif- MON-4
Items displayed ferent from machine condition
by gauges, cau-
tion lamps, and Items displayed by caution lamps
59 character dis- are different from machine condi- MON-4
play of machine tion
monitor are
abnormal Character display does not display MON-4
any item or it displays abnormally
60 Operation of machine monitor cannot be checked nor- MON-5
mally
Display of char- Machine monitor mode select MON-6
acter display can- switch 1 system is abnormal
61 not be selected Machine monitor mode select MON-6
normally 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 MON-9b)
signal lamps do not flash but light
up
When turn signal lever is oper-
ated, turn signal lamps on either or
both sides do not flash (When MON-9c)
hazard lamp switch is operated,
Turn signals and however, turn signal lamps flash
hazard lamp do normally)
64 not operate nor- W h e n h a z a r d l a m p s w it c h i s
mally 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 con-
tinue flashing (When turn signal MON-9e)
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)
lamp do not light up
65 Night lighting is
abnormal When lamp switch is OFF, small MON-10c)
lamp and night lamp light up
When dimmer switch is operated,
brightness of night lighting does MON-10d)
not change
Head lamp "Hi" beam does not MON-10e)
light up
20-316 HD465-7, HD605-7

(10)
Troubleshooting
Head lamp "Lo" beam does not MON-10f)
light up
Night lighting is Head lamp cannot be set to "Hi" or MON-10g)
65 abnormal "Lo"
When head lamp is set to "Hi"
beam, pilot lamp of machine moni- MON-10h)
tor does not light up
Left window does not work MON-
Power window 11a)
66 does not oper-
ate normally Right window does not work MON-
11b)
Air conditioner does not operate MON-
12a)
Air is not blown out or airflow can- MON-
not be adjusted 12b)
Air is not cooled or temperature MON-
cannot be adjusted (Electric sys-
tem) 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 (Mechani- MON-
cal 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 pres- VHMS-3
sure is normal)
Hydraulic and mechanical related
71 Machine does not start H-1
72 Machine does not travel smoothly H-2
73 Lock-up clutch cannot be disengaged 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

(10)
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

(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
No. X-type connector

of T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part no.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part no.: 79A-222-3370 Terminal part no.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: black • Grommet: black
• Quantity: 20 • Quantity: 20
Terminal part no.: 79A-222-3380 Terminal part no.: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-318 HD465-7, HD605-7

(10)
No. SWP-type connector

of T-adapter
Part No.
6 799-601-7050
Part No.: 08055- 10681 Part No.: Part No.: 08055- 10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055- 10891
12 799-601-7310
Part No.: 08055- 11281 Part No.: 08055- 11291
14 799-601-7070
Part No.: 08055- 11481 Part No.: 08055-11491
HD465-7, HD605-7 20-319

(1)
No. SWP-type connector

of T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part no.: Terminal part no.:
— —
• Grommet: black • Grommet: black
Terminal part no.: Terminal part no.:
— —
• Grommet: red • Grommet: red
20-320 HD465-7, HD605-7

(10)
No. M-type connector

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

(10)
S-type connector
No.
of pins T-adapter
Part No.
10
—
(blue)
— —
12
799-601-7160
(blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(blue)
Part No.: 08056-11672 Part No.: 08056-11682
HD465-7, HD605-7 20-323

(1)
MIC type connector

No.
of pins T-adapter
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7 —
Qty.: 5 Qty.: 5
11 —
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

(10)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730

Qty.: 2 Qty.: 2
21 799-601-2740

Qty.: 2 Qty.: 2
—
Qty.: 50 Qty.: 50
HD465-7, HD605-7 20-325

(1)
AMP040-type connector
No. of
pins T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

—
Qty.: 5
12 799-601-7190

—
Qty.: 5
16 799-601-7210

—
Qty.: 5
20 799-601-7220

—
Qty.: 5
aTerminal part No.: 79A-222-3470 (no relation with number of pins)
20-326 HD465-7, HD605-7

(1)
AMP070-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7360
20 799-601-7550
— Part No.: 7821-92-7370
HD465-7, HD605-7 20-327

(9)
L type connector
No. of
pins T-adapter
Part No.
—
2
— — —
PA type connector
No. of
pins T-adapter
Part No.
— —
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
— —
20-328 HD465-7, HD605-7

(10)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
2 —
Part No.: 08027-10210 (natural color) Part No.: 08027-10260 (natural color)
08027-10220 (black) 08027-10270 (black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (black) 08027-10470 (black)
6 —
08027-10620 (black) 08027-10670 (black)
HD465-7, HD605-7 20-329

(1)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
8 —
08027-10820 (black) 08027-10870 (black)
20-330 HD465-7, HD605-7

(1)
Connector for relay (socket type)

No. of
pins T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
HD465-7, HD605-7 20-331

(10)
F-type connector
No. of
pins T-adapter
Part No.
4 —
— —
20-332 HD465-7, HD605-7

(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
799-601-9210
(1) Pin (female terminal) Pin (male terminal)
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
HD465-7, HD605-7 20-333

(10)

Part No.
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-334 HD465-7, HD605-7

(10)

Part No.
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

Part No.: 08191-61201, 08191-62202 Part No.: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
HD465-7, HD605-7 20-335

(10)

Part No.
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Part No.: 08191-81201, 08191-81202, Part No.: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-81205, 08191-84103, 08191-84104, 08191-84105,
24-22 08191-81206 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202, Part No.: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-82205, 08191-83103, 08191-83104, 08191-83105,
08191-82206 08191-83106
20-336 HD465-7, HD605-7

(10)

Part No.
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
HD465-7, HD605-7 20-337

(10)
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-338 HD465-7, HD605-7

(10)
DT series connector
No. of
pins T-adapter
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9090
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
HD465-7, HD605-7 20-339

(10)
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

(10)
DRC26 Series connector

No.of
pins T-adapter Part
No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
HD465-7, HD605-7 20-340-1

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

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

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

(12)
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 K-9
08 Terminal 1 Emergency steering relay (M) A9 K-9
11 Terminal 1 Battery relay (E) B8 J-1 K-8 H-9 K-9 N-9
12 Terminal 1 Battery relay (BR) B8 J-1 K-8 H-8 K-8 N-8
12 KES0 2 Washer tank motor — J-1 K-8
13 Terminal 1 Battery relay (E) C8 J-1 K-8 H-8 K-8 N-8
14 Terminal 1 Battery relay (BR) C8 H-8 K-8 N-8
15 Terminal 1 Emergency steering relay (E) A8 K-9
16 Terminal 1 Emergency steering relay (BR) A7 K-9
17 Terminal 1 Emergency steering relay (E) B7 K-9
18 Terminal 1 Emergency steering relay (BR) B7 K-8
20 — 1 Circuit breaker A9 L-8 N-8
21 — 1 Circuit breaker A9 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

(10)
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

(5)
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 (Payload meter) (If equipped) — I-9
B1 One-pin 1 Lamp (Payload meter) (If equipped) — H-1

connector
B10 Terminal 1 Grounding K8 G-9 M-4
B11 Terminal 1 Grounding L8 M-5
B2 One-pin 1 Lamp (Payload meter) (If equipped) — J-9

connector
B2 One-pin
connector 1 Lamp (Payload meter) (If equipped) — H-1
B3 One-pin 1 Lamp (Payload meter) (If equipped) — J-9

connector
B3 One-pin 1 Lamp (Payload meter) (If equipped) — H-1
connector
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 (If equipped) 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

(10)
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 H-9 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 Coolant temperature sensor AE8 A-1
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

(10)
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 M-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) (Power window switch)
CNS2 DT-T 12 Intermediate connector B-9 B-2 H-8
(Green) (Gear shift lever)
DT-T Intermediate connector
CNS3 (Black) 12 (Parking brake switch) A-9 E-7
COM One-pin
connector 1 Air conditioner wiring harness M3 C-7
D01 DT-T 2 Diode W8 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 V8 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

(10)
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 (If equipped) 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

(10)
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 coolant 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 (If equipped) 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 (Payload meter) (If equipped) — I-9

connector
G One-pin 1 Lamp (Payload meter) (If equipped) — 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

(10)
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)
DT-T
JCC (Black) 8 Joint connector X5 K-6 B-1 A-2 C-1 G-1
JCD DT-T
(Black) 8 Joint connector X4 K-6 B-1 A-1 C-1 G-1
JCE DT-T 8 Joint connector X4 K-7 B-1 A-2 C-1 G-1

(Black)
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

(10)
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 (If equipped) N7 I-9
MON2 One-pin
connector 1 Rear view monitor (If equipped) N7 I-9
MON3 One-pin 1 Rear view monitor (If equipped) 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 (If equipped) D1 J-1
connector
PL07 Terminal 1 Grounding D2 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

(10)
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
(Gray) 12 Intermediate connector H9 I-3
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 (Payload meter) (If equipped) J-9
R One-pin 1 Lamp (Payload meter) (If equipped) 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

(10)
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 (If equipped) 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

(10)
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

Front brake cutting solenoid
S03 DT-T 2 (If equipped) E9 G-2
Auto suspension solenoid 1
S04 DT-T 2 (If equipped) F9 H-2
Auto suspension solenoid 2
S05 DT-T 2 (If equipped) F9 H-1
SBS DT-T 2 Seat belt switch U2 F-1
SDE M 6 Side lamp switch (If equipped) 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 (If equipped) J2 G-2
SLR M 1 Side lamp (If equipped) 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

(If equipped)
SUFR DT-T 3 Suspension oil pressure sensor(FR) B7 G-9 K-6
(If equipped)
SURL DT-T 3 Suspension oil pressure sensor(RL) L8 K-5 K-5
(If equipped)
SURR DT-T 3 Suspension oil pressure sensor(RR) J9 K-5 K-5
(If equipped)
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

(10)
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 PACKARD 3 Timing rail pressure sensor AI6 C-1
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 AO1 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

(10)
Address
Con- Type Num-
3-dimen-
HM81 M 8 VHMS - Orbcomm controller inter- AT2 L-3
mediate connector
HM-2130 YAZAKI 2 Resistor AQ2 H-8
HM-2140 YAZAKI 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

(10)
ABS control related

Address
Connec- Type Num-
tor of ber Location 3-dimen- System diagram
sional
diagram ENG TM BK PLM MON VHMS ASR ABS
ABS M 6 ABS system switch O2 E-9 BK7
ABS1 MIC 17 ABS controller BR3
ABS1 DT-T 6 Joint connector BF9
ABS2 MIC 21 ABS controller BR3
ABS2 DT-T 8 Joint connector BD2
ABS3 DT-T 6 Joint connector BE2
ABS3A 040 20 ABS controller BR8
ABS3B 040 16 ABS controller BQ9
ABS4 040 12 ABS controller BR8
ABS5 DT 6 Joint connector BF3
ABS5A 040 20 ABS controller BR8
ABS6 DT-T 6 Joint connector BG8
ABS7 DT-T 6 Joint connector BH8
ABSFL DT-T 2 ABS valve AX9
ABSFR DT-T 2 ABS valve AX9
ABSRL DT-T 2 ABS valve BH7
ABSRR DT-T 2 ABS valve BF9
BPFL DT-T 3 Brake oil pressure AW9
BPFR DT-T 3 Brake oil pressure AX9
BPRL DT-T 3 Brake oil pressure BH8
BPRR DT-T 3 Brake oil pressure BG9
BRC3B 040 16 Retarder controller Y4 A-5 BO9
BRC4 040 12 Retarder controller Z4 J-9 C-1 A-5 D-1 H-1 BP9
BRC5A 040 20 Retarder controller Y1 A-4 BQ9
CHK Yazaki 6 System check switch BL8
CVF DT-T 2 ABS cut solenoid AZ8
CVR DT-T 2 ABS cut solenoid BG9
CVSF DT-T 3 ABS cut switch AY8
CVSR DT-T 3 ABS cut switch BH8
DA1 DT-T 2 Diode BE9
DPC2B AMP070 12 Machine monitor P1 C-1 A-6 F-1 P1
FOGF M 6 Fog lamp switch BM1
FOGM M 6 Fog lamp switch BK8
J06 HD30 31 Intermediate connector BD1
JABS DT-T 12 Intermediate connector BA9
RABS KES1 6 ABS cut relay BS7
RABS2 KES1 6 ABS cut valve relay BS7
S01F DT-T 3 Service brake switch BC1
S01M DT-T 3 Service brake switch AZ1
S02F DT-T 3 Secondary brake switch BC9
S02M DT-T 3 Secondary brake switch BC9
WSFL DT-T 2 Wheel speed sensor BC1
WSFR DT-T 2 Wheel speed sensor AY7
WSRL2 DT-T 2 Wheel speed sensor BG9
WSRR2 DT-T 2 Wheel speed sensor BF9
20-355-3 HD465-7, HD605-7

(12)
TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION
CONNECTOR ARRANGEMENT LOCATION
20-356 HD465-7, HD605-7

(5)
HD465-7, HD605-7 20-357

(5)
20-358 HD465-7, HD605-7

(1)
HD465-7, HD605-7 20-359

(1)
20-360 HD465-7, HD605-7

(1)
HD465-7, HD605-7 20-361

(1)
VHMS control related

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

(2)
(2/2)
HD465-7, HD605-7 20-363

(2)
ABS control related

(1/2)
20-364 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-365

(12)
(2/2)
20-366 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-367

(12)
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 idle validation switch system: *See separate list (L4)
(Both signal voltages of 2 systems are sensed) ................................................................. 20-441
[C432L5] Error in idle validation process ( *See separate list (L5))...................................................... 20-443
[C441KX] 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

(10)
[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 idle 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

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL

Engine serial No. : 310169 – 310414
20-404 HD465-7, HD605-7

(9)
HD465-7, HD605-7 20-405

(2)
Engine serial No. : 310415 – 310798
20-405-1 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-2

(8)
Engine serial No. : 310799 and up
20-405-3 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-4

(8)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code Controller code
Display on Display on Display on Trouble Trouble in machine
panel panel panel
Contents of trouble Contents of trouble detected by monitor panel or controller
Action of controller
Action taken by controller to protect system or devices when monitor panel or controller detects trouble
or monitor panel
Problem that
Problem that appears on machine as result of action taken by monitor panel or controller (shown above)
appears on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in harness>
• Disconnection
Connector is connected imperfectly or harness is broken.
• Ground fault
Harness which is not connected to chassis ground circuit is in con-
2 tact with chassis ground circuit.
• Short circuit with power source (Hot short)
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
• Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes Possible causes of trouble
and standard value (Given numbers are refer-
3 <Precautions for troubleshooting>
in normal state ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter
indicate priority) Insert or connect T-adapter as explained below for troubleshooting,
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
side.
4 • 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 ex-
plained below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front
side.
5
• Connect negative (–) lead to pin No. or harness entered on rear
side.
20-406 HD465-7, HD605-7

(10)
Related electrical circuit diagram
Part of electric circuit diagram related to trouble

• Connector No.: Indicates (Model – Number of pins) and (Color).
• Arrows ( ): Indicate rough location of connector in machine.
PHENOMENON CODE TABLE

a Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Phenomenon
code Contents code Contents
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, coolant 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.
Short circuit with power
KY source (Hot short) 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
HD465-7, HD605-7 20-407

(10)
TROUBLESHOOTING [C111KT], [C112LK]
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY
Action code Failure code Controller code Abnormality in engine controller memory
Trouble
E03 C111KT ENG (Engine controller system)
Contents of trouble • Memory in controller has trouble or processor in controller has communication trouble.
Action of controller • Flashes warning lamp and turns on alarm buzzer.
Problem that
• Engine cannot be started.
appears on machine
Related information • Method of reproducing failure code: Turn starting switch ON.

Reset according to following procedure. If failure code E is displayed
Possible causes
at this time, engine controller is defective.
and standard value
in normal state 1 Defective engine controller 1) Keep starting switch at OFF position for 5 seconds.
2) Run engine at low idle.
3) Check failure code.
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR
Action code Failure code Controller code Abnormality in timing rail actuator
Trouble
E03 C112LK ENG (Engine controller system)
• Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble • Judgment value (for reference):
Error is above 400 mm3/st or below – 750 mm3/st (When coolant temperature is below 0°C).
• Flashes warning lamp and turns on alarm buzzer.
• Limits engine speed to 1,500 rpm.
Problem that
• Engine speed lowers.
appears on machine
Related information • Method of reproducing failure code: Start engine.

Check displayed failure codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
Possible causes leakage.
piping
and standard value
3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
in normal state
Clogging of timing rail actua-
4 Check timing rail actuator screen directly for clogging.
tor screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
20-408 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C113KZ]
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM
Action code Failure code Controller code Abnormal current in timing rail actuator system
Trouble
E03 C113KZ ENG (Engine controller system)
• Current in timing rail actuator is out of normal range.
Contents of trouble
• Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Problem that • Engine output lowers.
appears on machine • Exhaust gas becomes white.
• Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.
Related information
• Method of reproducing failure code: Turn starting switch ON (or start engine).

aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective timing rail actuator TIMG (male) Resistance
1
(Internal trouble)
Between (A) – (C) 7–9z
Between (A), (C) – chassis ground Min. 100 kz
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between ECMA (female) (1) –
2 (Disconnection in wiring or Resistance Max. 10 z
TIMG (female) (A)
defective contact in connec-
tor) Wiring harness between ECMA (female) (20) –
Resistance Max. 10 z
TIMG (female) (C)
Possible causes
and standard value aPrepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON
Short circuit in wiring har- Wiring harness between ECMA (female) (1) –
ness TIMG (female) (A) with wiring harness around Resistance Min. 1 M z
3
(with another wiring har- it
ness) Wiring harness between ECMA (female) (20) –
TIMG (female) (C) with wiring harness around Resistance Min. 1 M z
it
ECMA (female) Resistance
Between (1) – (20) 7–9z
Wiring harness between (1), (20) –
Min. 1 M z
wiring harness around it
Circuit diagram related to timing rail actuator
HD465-7, HD605-7 20-409

(11)
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS
Action code Failure code Controller code Abnormality in engine speed sensor 2 systems
Trouble
Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems.
• Outputs speed signal of 0 rpm.
Problem that
• Engine stops.
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 01001, 01002: Engine speed)
Related information
• Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.
• Method of reproducing failure code: Start engine.

without turning starting switch ON
SP (male) Resistance
Defective engine speed sen-
1 sor Between (2) – (1) and (3) – (4) 1 – 2 kz
(Internal trouble) Between (2) – (3) Max. 10 z
Between (1) – (4) Max. 10 z
Between (2), (3) – chassis ground Min. 10 Mz
Damage of engine speed
2 Check engine speed sensor directly.
sensor
Disconnection in wiring har- Resistance Max. 10 z
SP (female) (2)
ness
SP (female) (1)
Possible causes SP (female) (3)
and standard value Wiring harness between ECMA (female) (38) –
in normal state Resistance Max. 10 z
SP (female) (4)
Resistance Min. 1 Mz
Short circuit in wiring har- SP (female) (2) with wiring harness around it
ness Wiring harness between ECMA (female) (28) –
4 Resistance Min. 1 Mz
(with another wiring har- SP (female) (1) with wiring harness around it
SP (female) (3) with wiring harness around it
SP (female) (4) with wiring harness around it
aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective engine controller Between (27) – (28) 1 – 2 kz
Between (37) – (38) 1 – 2 kz
20-410 HD465-7, HD605-7

(10)
Circuit diagram related to engine speed sensor
HD465-7, HD605-7 20-411

(8)
TROUBLESHOOTING [C116KX]
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in timing rail pressure sensor system
Trouble
E03 C116KX ENG (Engine controller system)
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Action of controller • Opens and controls timing rail.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective timing rail pres-
1 sure sensor TPR Voltage
(Internal trouble) Between (A) – (B) 4.75 – 5.25 V
Between (C) – (B) 0.42 – 0.58 V
Disconnection in wiring har-
ness Resistance Max. 10 z
TPR (female) (A)
2 (Disconnection in wiring or
defective contact in connec- Wiring harness between ECMA (female) (18) –
tor) TPR (female) (B)
Possible causes Wiring harness between ECMA (female) (33) –
and standard value TPR (female) (C)
in normal state aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- Wiring harness between ECMA (female) (5)–
ness TPR (female) (A) with wiring harness around it
3
(with another wiring har- Wiring harness between ECMA (female) (18) –
ness) Resistance Min. 1 Mz
TPR (female) (B) with wiring harness around it
TPR (female) (C) with wiring harness around it
4 Defective engine controller ECMA Voltage
Between (5) – (18) 4.75 – 5.25 V
Between (33) – (18) 0.42 – 0.58 V
Circuit diagram related to timing rail pressure
20-412 HD465-7, HD605-7

(11)
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in timing rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.30 V
Action of controller • Opens and controls timing rail.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard value
in normal state Carry out troubleshooting for failure code [C116KX].
HD465-7, HD605-7 20-413

(10)
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
• Opens and controls fuel pump.
Problem that
appears on machine
• Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.
Related information

Defective fuel pump pres-
1 sure sensor PMPR (male) Voltage
Between (C) – (B) 0.42 – 0.58 V
PMPR (female) (A)
PMPR (female) (B)
tor)
Possible causes PMPR (female) (C)
in normal state without turning starting switch ON.
Short circuit in wiring har- PMPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
3 Wiring harness between ECMA (female) (18) –
(with another wiring har-
ness) PMPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
PMPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
4 Defective engine controller ECMA (female) Resistance
Between (5) – (18) 4.75 – 5.25 V
Between (32) – (18) 0.42 – 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-414 HD465-7, HD605-7

(11)
TROUBLESHOOTING [C119KX], [C121LC]
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
• Opens and controls fuel pump.
Problem that
appears on machine

and standard value
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS
Action code Failure code Controller code Abnormality in engine speed sensor 1 systems
Trouble
E01 C121LC ENG (Engine controller system)
Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems.
Problem that
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related information (Code 01001: Engine speed)

and standard value
in normal state Carry out troubleshooting for failure code [C115KZ].
HD465-7, HD605-7 20-415

(10)
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in boost pressure sensor system
Trouble
Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.72 V.
Problem that • When machine is accelerated suddenly, exhaust gas color is bad.
appears on machine • Engine output rises.
• Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor.
Related information

Defective boost pressure
1 sensor IMPR (male) Voltage
Between (C) – (B) 0.42 – 0.58 V
IMPR (female) (A)
IMPR (female) (B)
tor)
Possible causes IMPR (female) (C)
Short circuit in wiring har- IMPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
ness) IMPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
IMPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (6) – (17) 4.75 – 5.25 V
Between (35) – (17) 0.42 – 0.58 V
Circuit diagram related to boost pressure sensor
20-416 HD465-7, HD605-7

(11)
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in boost pressure sensor system
Trouble
Contents of trouble • Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
• Engine output lowers.
appears on machine

and standard value
HD465-7, HD605-7 20-417

(10)
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in throttle sensor system
Trouble
Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4.80 V.
• Keeps engine speed at constant level.
Problem that
• Engine output and speed rise 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 failure code: Turn starting switch ON.

Defective throttle potentiom- AS1 (male) Resistance
1 eter
Between (3) – (1) 4.0 – 6.0 kz
(Internal trouble)
Between (3) – (2) 0.25 – 7.0 kz
Between (2) – (1) 0.25 – 7.0 kz
Wiring harness between ECMB (female) (26) –
AS1 (female) (3)
defective contact in connec- Resistance Max. 10 z
AS1 (female) (1)
tor)
Possible causes Wiring harness between ECMB (female) (29) –
and standard value Resistance Max. 10 z
AS1 (female) (2)
Short circuit of wiring harness between ECMB
Short circuit in wiring har- (female) (26) – AS1 (female) (3) with wiring Resistance Min. 1 Mz
harness around it
ness
3 Short circuit of wiring harness between ECMB
ness) (female) (11) – AS1 (female) (1) with wiring Resistance Min. 1 Mz
harness around it
Short circuit of wiring harness between ECMB
(female) (29) – AS1 (female) (2) with wiring Resistance Min. 1 Mz
harness around it
ECMB Voltage
Between (29) – (11) 0.30 – 4.80 V
20-418 HD465-7, HD605-7

(10)
Circuit diagram related to deceleration potentiometer
HD465-7, HD605-7 20-419

(1)
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in throttle sensor system
Trouble
Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.
• 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)

and standard value
20-420 HD465-7, HD605-7

(10)
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information

Defective engine oil pres-
1 sure sensor OLPR Voltage
Between (C) – (B) 0.42 – 0.58 V
OLPR (female) (A)
tor) OLPR (female) (B)
Possible causes OLPR (female) (C)
Short circuit of wiring harness between ECMA
Short circuit in wiring har- (female) (6) – OLPR (female) (A) with wiring Resistance Min. 1 Mz
harness around it
ness
3 Short circuit of wiring harness between ECMA
ness) (female) (17) – OLPR (female) (B) with wiring Resistance Min. 1 Mz
harness around it
Short circuit of wiring harness between ECMA
(female) (24) – OLPR (female) (C) with wiring Resistance Min. 1 Mz
harness around it
Between (6) – (17) 4.75 – 5.25 V
Between (24) – (17) 0.42 – 0.58 V
Circuit diagram related to engine oil pressure sensor
HD465-7, HD605-7 20-421

(10)
TROUBLESHOOTING [C141KX], [C143ZG]
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in engine oil pressure sensor system
Trouble
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
Problem that
appears on machine

and standard value
[C143ZG] LOWERING OF ENGINE OIL PRESSURE
Action code Failure code Controller code Lowering of engine oil pressure
Trouble
E03 C143ZG ENG (Engine controller system)
• Engine oil pressure sensor detected pressure lower than pressure set in controller.
• Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

Possible causes 1 Defective related systems
and standard value
in normal state Defective engine oil pres-
2 Carry out troubleshooting for failure codes [C135KX] and [C141KX].
sure sensor system
3 Defective engine See Shop Manual for engine (170-3 Series).
20-422 HD465-7, HD605-7

(10)
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE

SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor.
Related information

Defective engine coolant without turning starting switch ON.
1 temperature sensor
CLTP Resistance
(Internal trouble)
Between (A) – (B) 600 – 36 kz
ness
2 (Disconnection in wiring or Wiring harness between ECMA (female) (22) – Resistance Max. 10 z
CLTP (female) (A)
Possible causes Resistance Max. 10 z
CLTP (female) (B)
and standard value
in normal state
Short circuit in wiring har- Short circuit of wiring harness between ECMA
ness (female) (22) – CLTP (female) (A) with wiring Resistance Min. 1 Mz
3
(with another wiring har- harness around it
ness) Short circuit of wiring harness between ECMA
(female) (17) – CLTP (female) (B) with wiring Resistance Min. 1 Mz
harness around it
Between (22) – (17) 600 – 36 kz
Circuit diagram related to engine coolant temperature sensor
HD465-7, HD605-7 20-423

(10)
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-424 HD465-7, HD605-7

(10)
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE

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 throttle sensor signal is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).
Problem that
• The engine speed is kept at low idle 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
contact) Resistance Max. 10 z
ATC3A (female) (5)
2) Disconnect connectors ECMB and ATC3A.
Ground fault in wiring har- 3) Connect T-adapter.
2
ness Wiring harness between Resistance between ECMB
ECMB (female) (17) – (female) (17), ATC3A (fe- Min. 1 Mz
Possible causes
ATC3A (female) (5) male) (5) – chassis ground
and standard value
in normal state 1) Turn the starting switch OFF.
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) (5) – chassis
Frequency 170 – 380Hz
ground
1) Connect all the connectors.
2) Turn the starting switch ON.
4 Engine controller defective • Check that the failure code disappears.
aIf the failure code does not disappear, replace the engine control-
ler.
Circuit diagram related to engine abnormality in FM throttle
HD465-7, HD605-7 20-425

(10)
TROUBLESHOOTING [C151NS]
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE
Action code Failure code Controller code Rise of engine coolant temperature
Trouble
E02 C151NS ENG (Engine controller system)
• Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 105°C
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

and standard value
in normal state Defective engine coolant
temperature sensor system
20-426 HD465-7, HD605-7

(10)
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally high level in air intake temperature sensor system
Trouble
Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4.88 V.
Problem that
appears on machine
• Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Related information

Defective air intake temper- without turning starting switch ON.
1 ature sensor
IMTP (female) Resistance
(Internal trouble)
Between (A) – (B) 36 – 600 z
ness
IMTP (female) (A)
IMTP (female) (B)
and standard value
in normal state
ness IMTP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
IMTP (female) (B) with wiring harness around Resistance Min. 1 Mz
it
Between (23) – (17) 36 – 600 z
Circuit diagram related to air intake temperature sensor
HD465-7, HD605-7 20-427

(10)
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in air intake temperature sensor system
Trouble
Contents of trouble • Signal voltage of air intake temperature sensor circuit is below 0.08 V.
Problem that
appears on machine

and standard value
20-428 HD465-7, HD605-7

(10)
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM)
Action code Failure code Controller code Abnormally high level in atmospheric pressure sensor system
Trouble
Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is above 4.78 V
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Related information

carry out troubleshooting
Defective atmospheric pres-
1 sure sensor AAPR Voltage
Between (C) – (B) 0.42 – 0.58 V
AAPR (female) (A)
tor) AAPR (female) (B)
Possible causes AAPR (female) (C)
Short circuit in wiring har- AAPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
ness) AAPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
AAPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (6) – (17) 4.75 – 5.25 V
Between (34) – (17) 0.42 – 0.58 V
Circuit diagram related to atmospheric pressure sensor
HD465-7, HD605-7 20-429

(10)
TROUBLESHOOTING [C222KX] , [C234NI]
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
Problem that
appears on machine

and standard value
[C234NI] OVER-SPEED
Action code Failure code Controller code Over-speed

Trouble
E02 C234NI ENG (Engine controller system)
• Engine speed sensor detected speed higher than speed set in controller.
Contents of trouble
• Criterion (for reference): Min. 2,400 rpm
Action of controller • Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine

Possible causes
and standard value 1 Defective related systems
in normal state
20-430 HD465-7, HD605-7

(10)
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE
Action code Failure code Controller code Abnormal voltage of fuel shut-off valve
Trouble
Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 z).
Action of controller • Turns off power for fuel shut-off valve.
Problem that
• Engine stops.
appears on machine

Defective fuel shut-off valve FSO (Valve side) Resistance
1
(Internal trouble)
Between (+) – (–) 23 – 40 z
Between (+) – chassis ground 100 kz
ness
FSO (wiring harness side) (+)
Possible causes tor) Wiring harness between FSO (wiring harness
and standard value side) (–) – chassis ground
ness FSO (wiring harness side) (+) with wiring har- Resistance Min. 1 Mz
3
(with another wiring harness around it
ness) Wiring harness between FSO (wiring harness
side) (–) – chassis ground with wiring harness Resistance Min. 1 Mz
around it
ECMA Resistance
Between (30) – chassis ground 23 – 40 z
Circuit diagram related to fuel shut-off valve
HD465-7, HD605-7 20-431

(10)
TROUBLESHOOTING [C259FS], [C261NS]
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE
Action code Failure code Controller code Abnormality in fuel shut-off valve
Trouble
E03 C259FS ENG (Engine controller system)
Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
• Turns off power for fuel shut-off valve.
Problem that
• Engine cannot be stopped.
appears on machine

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
and standard value Clogging, looseness, break-
in normal state 3 age, or leakage of fuel filter/
leakage.
piping
4 Trouble in injector Check inside of injector directly.
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE
Action code Failure code Controller code Abnormal rise of fuel temperature
Trouble
E02 C261NS ENG (Engine controller system)
• Fuel temperature sensor detected temperature lower than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 76°C
Action of controller • Limits engine speed to 800 rpm after 30 seconds.
Problem that
appears on machine

and standard value
in normal state Defective fuel temperature
sensor system
20-432 HD465-7, HD605-7

(10)
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel temperature sensor system
Trouble
Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Related information

Defective fuel temperature without turning starting switch ON.
1 sensor
FLTP (female) Resistance
(Internal trouble)
Between (A) – (B) 600 – 36 kz
ness
FLTP (female) (A)
FLTP (female) (B)
and standard value
in normal state
ness FLTP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
FLTP (female) (B) with wiring harness around Resistance Min. 1 Mz
it
Between (26) – (17) 600 – 36 kz
Circuit diagram related to fuel temperature sensor
HD465-7, HD605-7 20-433

(10)
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel temperature sensor system
Trouble
Contents of trouble • Signal voltage of fuel temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-434 HD465-7, HD605-7

(10)
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR
Action code Failure code Controller code Abnormal current of fuel pump actuator
Trouble
• Current of fuel pump actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Related information

Defective fuel pump actuator PUMP (male) Resistance
1
(Internal trouble)
ness
PUMP (female) (A)
Possible causes PUMP (female) (C)
ness PUMP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
PUMP (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (11) – (40) 7–9z
Between (11), (40) – another wir-
Min. 1 Mz
ing harness
Circuit diagram related to fuel pump actuator
HD465-7, HD605-7 20-435

(10)
TROUBLESHOOTING [C318LK]
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR
Action code Failure code Controller code Abnormality in fuel pump actuator
Trouble
• Displayed pressure of fuel pump is excessively different from actual value.
Contents of trouble
• Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when coolant temperature is 38°C)
Problem that
• Engine speed is unstable.
appears on machine

Check fuel filter and piping directly for clogging, looseness, breakage,
and leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
3
fuel level in tank gauge is in red range, supply fuel.
Possible causes Suction resistance of fuel filter may be large. Check fuel filter directly.
and standard value Large suction resistance of
4 Negative suction pressure
in normal state fuel filter 27 kPa {203 mmHg}
(Tank side)
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
Circuit diagram related to fuel pump actuator
20-436 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C346KT]
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER
Action code Failure 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.
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)

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)
Disconnection in wiring har- Wiring harness between ECMB (female) (3) –
BT2-(6) outlet
Wiring harness between ECMA (female) (4),
tor) (5) – BT2-(30) outlet
Wiring harness between FS1 inlet – fusible link
(FUA) – battery relay terminal B
Possible causes
Short circuit in wiring har- BT2-(6) outlet with wiring harness around it
ness Wiring harness between ECMA (female) (4),
4
(with another wiring har- (5) – BT2-(30) outlet with wiring harness Resistance Min. 1 Mz
ness) around it
Wiring harness between FS1 inlet – fusible link
– battery relay terminal B with wiring harness Resistance Min. 1 Mz
around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB (3), (4), (5) –
17.3 – 34.7 V
ECMA (7), (8)
HD465-7, HD605-7 20-437

(10)
TROUBLESHOOTING [C346KT]
Circuit diagram related to engine controller power supply
20-438 HD465-7, HD605-7

(1)
TROUBLESHOOTING [C423L6]
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormality in in-range of timing rail pressure sensor system
Trouble
E03 C423L6 ENG (Engine controller system)
• Timing rail pressure sensor detected abnormal pressure.
Contents of trouble
• Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
• Limits high idle speed to 1,500 rpm.
Problem that
appears on machine
• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TPR (male) Voltage
Between (C) – (B) 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5) –
TPR (female) (A)
tor) TPR (female) (B)
TPR (female) (C)
Possible causes
and standard value
in normal state
ness TPR (female) (A) with wiring harness around it
3
TPR (female) (B) with wiring harness around it
TPR (female) (C) with wiring harness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
5 Defective engine controller ECMA (female) Resistance
Between (5) – (18) 4.75 – 5.25 V
Between (33) – (18) 0.42 – 0.58 V
HD465-7, HD605-7 20-439

(11)
Circuit diagram related to timing rail pressure sensor
20-440 HD465-7, HD605-7

(1)
[C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE

LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)
Action code Failure code Controller code Abnormality in idle validation switch system: *See separate list
Trouble
E01 C431L4 ENG (L4) (Both signal voltages of 2 systems are sensed)
Contents of trouble • Both idle validation switch signals 2 and 3 are open (above 4.5 V).
Action of controller • (The controller displays action code E01, CHECK/REPAIR.)
Problem that • None in particular. (Since the controller controls according to the throttle sensor signal (potentiometer),
appears on machine no problems appear in the truck body.
Related information

2) Disconnect connector AS1.
3) Connect T-adapter.
Release the accelerator
Between AS1 pedal "Idle ON".
Idle validation switch defec-
1 (male) (4) – (5) Press the accelerator pedal
tive Resistance Min. 1 Mz
"Idle OFF".
(male) (4) – (6) Press the accelerator pedal
"Idle OFF".
2) Disconnect connectors ECMB and AS1.
2 AS1 (female) (6)
Possible causes contact) Resistance Max. 1 z
AS1 (female) (5)
and standard value
AS1 (female) (4)
Wiring harness between Resistance between ECMB
ECMB (female) (12) – AS1 (female) (12), AS1 (female) Min. 1 M z
Ground fault in wiring har- (female) (6) (6) – chassis ground
3
ECMB (female) (13) – AS1 (female) (13), AS1 (female) Min. 1 Mz
(female) (5) (5) – chassis ground
1) Connect the all connectors.
3) Press the accelerator pedal 3 times repeatedly.
4 Engine controller defective
• Check that the failure code disappears.
a If the failure code does not disappear, replace the engine control-
ler.
HD465-7, HD605-7 20-441

(10)
Circuit diagram related to engine idle validation switch
20-442 HD465-7, HD605-7

(10)
[C432L5] ERROR IN IDLE VALIDATION PROCESS ( *SEE SEPARATE LIST (L5))
Action code Failure code Controller code Error in idle validation process: *See separate list (L5)
Trouble (Potentiometer signal and switch signal do not agree with each
E03 C432L5 ENG other)
• The throttle potentiometer signal of the accelerator pedal is not conformed to idle validation switch sig-
Contents of trouble
nal 2 and signal 3.
• The throttle is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).
• If this failure is detected when the throttle sensor signal is on the low speed side (idle side), the throttle
is conformed to the throttle sensor.
Problem that
• The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

"Idle OFF".
"Idle OFF".
2 AS1 (female) (6)
AS1 (female) (5)
Possible causes Wiring harness between ECMB (female) (21) –
AS1 (female) (4)
in normal state
3
4) Connect connector.
4 Slottle sensor defective 5) Startin switch ON.
Between Release the accelerator
Voltage 0.35 – 0.55V
AS1 pedal "Idle ON".
(male) (1) Press the accelerator pedal
Voltage 3.55 – 3.75V
– (2) "Idle OFF".
HD465-7, HD605-7 20-443

(10)

Possible causes 2) Turn the starting switch ON.
and standard value 3) Press the accelerator pedal 3 times repeatedly.
in normal state 5 Engine controller defective
ler.
Circuit diagram related to engine idle validation process
20-444 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C441KX], [C442KG]
[C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Failure code Controller code Abnormally low level in battery voltage system
Trouble
Contents of trouble • Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C346KT].
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Failure code Controller code Abnormally low level in battery voltage system
Trouble
E01 C442KG ENG (Engine controller system)
Contents of trouble • Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C346KT].
HD465-7, HD605-7 20-445

(10)
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
• Opens and controls fuel rail.
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between (C) – (B) 0.42 – 0.58 V
RPR (female) (A)
RPR (female) (B)
tor)
Possible causes Wiring harness between ECMA (female) (31) –
and standard value RPR (female) (C)
ness RPR (female) (A) with wiring harness around it
3
RPR (female) (B) with wiring harness around it
RPR (female) (C) with wiring harness around it
Between (5) – (18) 4.75 – 5.25 V
Between (31) – (18) 0.42 – 0.58 V
Circuit diagram related to fuel rail pressure sensor
20-446 HD465-7, HD605-7

(10)
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
• Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine

and standard value
HD465-7, HD605-7 20-447

(10)
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR
Action code Failure code Controller code Abnormal current of fuel rail actuator
Trouble
• Current of fuel rail actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Related information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance
1
(Internal trouble)
ness
RAIL (female) (A)
RAIL (female) (C)
and standard value
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between ECMA (female) (3) –
3 Resistance Min. 1 Mz
(with another wiring har- RAIL (female) (A) with wiring harness around it
RAIL (female) (C) with wiring harness around it
Between (3) – (10) 7–9z
Between (3), (10) – another wiring
Min. 1 Mz
harness
Circuit diagram related to fuel rail actuator
20-448 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C467LK], [C468LK]
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL
Action code Failure code Controller code Abnormality in timing rail actuator control
Trouble
• Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot
Contents of trouble
be obtained.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C112LK].
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL
Action code Failure code Controller code Abnormality in fuel rail actuator control
Trouble
• Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
Contents of trouble
obtained.
• Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

Possible causes leakage.
piping
and standard value
3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
in normal state
Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
HD465-7, HD605-7 20-449

(10)
TROUBLESHOOTING [C514LK]
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR
Action code Failure code Controller code Abnormality in fuel rail actuator
Trouble
• Displayed injection rate of fuel rail is excessively different from actual injection rate.
Contents of trouble
• Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.
• Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C468LK].
20-450 HD465-7, HD605-7

(10)
[C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE

LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)
Action code Failure code Controller code Abnormality in idle validation switch system: *See separate list
Trouble
E01 C551L4 ENG (L4) (Either signal voltage of 2 systems is not sensed)
Contents of trouble • Both of idle validation switch signals 2 and 3 are closed (connected to GND).
• Controller sets engine speed to low idle.
Problem that
• Engine speed is kept at low idle.
appears on machine
Related information

"Idle OFF".
"Idle OFF".
2 AS1 (female) (6)
Possible causes contact) Resistance Max. 1 z
AS1 (female) (5)
and standard value
AS1 (female) (4)
3
3) Press the accelerator pedal 3 times repeatedly.
ler.
HD465-7, HD605-7 20-451

(10)
Circuit diagram related to idle validation switch
20-452 HD465-7, HD605-7

(10)
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormality in in-range of fuel rail pressure sensor system
Trouble
E03 C554L6 ENG (Engine controller system)
• Fuel rail pressure sensor detected abnormal pressure.
Contents of trouble
• Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
• Limits maximum injection rate to 270 mm3/st
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between (C) – (B) 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5) –
RPR (female) (A)
tor) RPR (female) (B)
RPR (female) (C)
Possible causes
and standard value
in normal state
ness RPR (female) (A) with wiring harness around it
3
RPR (female) (B) with wiring harness around it
RPR (female) (C) with wiring harness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
Between (5) – (18) 4.75 – 5.25 V
Between (31) – (18) 0.42 – 0.58 V
HD465-7, HD605-7 20-453

(11)
Circuit diagram related to fuel rail pressure sensor
20-454 HD465-7, HD605-7

(1)
TROUBLESHOOTING ENG-1
ENG-1 ENGINE DOES NOT START

Trouble Engine does not start
Not set Not set ENG
Contents of trouble • Engine does not start.
Action of controller • None in particular.
Problem that
• Engine does not start.
appears on machine
• If any failure code related to the engine controller or transmission controller is indicated, perform trou-
Related information
bleshooting for it first.

Specific gravity Min. 1.26
1 Battery defective
Voltage Min. 25 V
2) Replace R01 with normal one.
When engine starting relay (R01) No Relay (R01) normal
is replaced, is failure repaired? Yes Relay (R01) defective
2) Disconnect connector R01.
3) Check R01.
Engine starting relay (R01)
2
defective Between R01 (male) (1) – (2) Resistance 200 – 400 z
3) Check R01.
4) Apply voltage between R01 (male) (1) – (2).
Apply 24 V between
Between R01 (male) (1) – (2).
(3) – (6) Do not apply voltage
Resistance Max. 1 z
between (1) – (2).
Possible causes
and standard value 1) Turn the starting switch OFF.
in normal state 2) Replace R02 with normal one.
When transmission neutral relay No Relay (R02) normal
(R02) is replaced, is failure repaired? Yes Relay (R02) defective
3) Check R02.
Transmission neutral relay
3
(R02) defective Between R02 (male) (1) – (2) Resistance 200 – 400 z
3) Check R02.
Apply 24 V between
Resistance Max. 1 z
between (1) – (2).
2) Replace diode (D01).
4 Diode (D01) defective 3) Turn the starting switch to the START position.
Failure is not repaired. Diode (D01) is normal.
Failure is repaired. Diode (D01) is defective.
HD465-7, HD605-7 20-455

(10)

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

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

(10)
Circuit diagram related to engine does not start
20-458 HD465-7, HD605-7

(1)
ENG-2 FAILURE IN PREHEATING

a) Engine is not preheated
Action code Failure code Controller code 1. Failure in preheating

Trouble
Not set Not set ENG a) Engine is not preheated
Contents of trouble • Engine is not preheated. (Engine coolant temperature is below 0°C.)
Problem that
• Engine is not preheated.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A – chassis ground Resistance 19 – 25 z
When relay is
Resistance Max. 1 z
Between E12A – opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
tive Resistance Min. 1M z
OFF
Between E11B – chassis ground Resistance 19 – 25 z
When relay is
Resistance Max. 1 z
Between E12B – opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the heater terminal.
Intake air heater (Ribbon 3) Check the heater.
2
heater) defective
Between heater terminal – chassis
Resistance 0.17 – 0.27z
ground
Possible causes 1) Turn the starting switch OFF.
and standard value 2) Replace R37 with a normal relay.
in normal state 3) Turn the starting switch ON.
When the automatic preheater re- No Relay (R37) is normal.
lay (R37) is replaced, is failure re- Relay (R37) is defec-
paired? Yes
tive.
Automatic preheater relay 3) Check connector R37.
3
3) Check connector R37.
Apply 24 V between
Resistance Min. 1M z
Resistance Max. 1 z
between (1) – (2).
Diode (E17A, E17B) defec- 2) Replace diode (E17A, E17B).
4
tive Failure is not repaired. Diode (D01) is normal.
HD465-7, HD605-7 20-459

(10)

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

(10)
Circuit diagram related to preheating
HD465-7, HD605-7 20-461

(1)
b) Preheating is actuated even under non-actuation conditions for preheating
Action code Failure 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.
Problem that
• Preheating is actuated even under non-actuation conditions for preheating.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A – chassis ground Resistance 19 – 25 z
When relay is
Resistance Max. 1 z
Between E12A – opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
OFF
Between E11B – chassis ground Resistance 19 – 25 z
When relay is
Resistance Max. 1 z
Between E12B – opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the connector.
and standard value
in normal state Wiring harness between Voltage between ECMA (fe-
ECMA (female) (2) – R37 male) (2), R37 (female) (1) – Max. 1 V
(female) (1) chassis ground
2 Hot short in wiring harness
Wiring harness between Voltage between R37 (fe-
R37 (female) (5) – E11A, male) (5), E11A, E11B – Max. 1 V
E11B chassis ground
Wiring harness between Voltage between AC5A (fe-
AC5A (female) (20) – HES male) (20), HES – chassis Max. 1 V
(a) ground
Measure only on E12A side for wiring harness marked with (a).
2) Disconnect connector ECMA.
6) Engine coolant temperature: Max. 0 °C
Between At the heater operation Voltage 20 – 30V
ECMA (2)
– (7), (8) At the heater un operation Voltage Max. 1 V
20-462 HD465-7, HD605-7

(10)
Circuit diagram related to preheating time
HD465-7, HD605-7 20-463

(1)
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY

a) When AISS switch is set in AUTO, LOW SPEED control is selected
Action code Failure code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set a) When AISS switch is set in AUTO, LOW SPEED control is se-
lected
Contents of trouble • When AISS switch is set in AUTO, LOW SPEED control is selected
Problem that
• When AISS switch is set in AUTO, LOW SPEED control is selected
appears on machine
Related information • Failure code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 z
(male) (1) – (2) Set the AISS switch in LOW. Resistance Min. 1 Mz
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Between R07 (male) (1) – (2) Resistance 200 – 400 z
Possible causes 3) Check the relay.
and standard value 4) Apply voltage between R07 (male) (1) – (2).
in normal state Apply 24 V between (1) –
Between R07 (2).
(male) (3) – (6) Do not apply 24 V between
Resistance Max. 1 z
(1) – (2).
2) Disconnect connectors AISS, R07, – fuse BT2 terminal (2).
Disconnection in wiring har- Wiring harness between fuse BT2 (2) – AISS
3 (female) (1)
Wiring harness between AISS (female) (2) –
R07 (female) (1)
Wiring harness between R07 (female) (2) –
Resistance Max. 1 z
chassis ground
2) Disconnect connector ECMB.
Between ECMB Set the AISS switch in Voltage 20 – 30 V
(33) – chassis AUTO.
ground Set the AISS switch in LOW. Voltage Max. 1 V
20-464 HD465-7, HD605-7

(10)
b) When AISS switch is set in LOW SPEED, AUTO control is selected
Action code Failure code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set b) When AISS switch is set in LOW SPEED, AUTO control is se-
lected
Contents of trouble • When AISS switch is set in LOW SPEED, AUTO control is selected
Problem that
• When AISS switch is set in LOW SPEED, AUTO control is selected
appears on machine
Related information • Failure code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 z
(male) (1) – (2) Set the AISS switch in LOW Resistance Min. 1 Mz
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Possible causes 2) Disconnect connector R07.
and standard value 3) Check the relay.
in normal state 4) Apply voltage between R07 (male) (1) – (2).
Apply 24 V between (1) –
Between R07 (2).
(male) (3) – (6) Do not apply 24 V between
Resistance Max. 1 z
(1) – (2).
Disconnection in wiring har- 2) Disconnect connector R07.
3
chassis ground
2) Disconnect connectors AISS and R07.
Wiring harness be-
Wiring harness be-
tween AISS (female)
tween AISS (female) Voltage Max. 1 V
4 Hot short in wiring harness (2), R07 (female) (1) –
(2) – R07 (female) (1)
chassis ground
Wiring harness be-
Wiring harness be-
tween ECMB (female)
tween ECMB (female) Voltage Max. 1 V
(33), R07 (female) (6)
(33) – R07 (female) (6)
– chassis ground
HD465-7, HD605-7 20-465

(10)

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

(1)
TROUBLESHOOTING FOR TRANSMISSION
CONTROLLER SYSTEM
(TM MODE)
Electrical system diagram related to transmission control .......................................................................... 20-503

Information in troubleshooting table ....................................................................................................... 20-504
Phenomenon 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 to F gear shift abuse 1: Mistake in operation or setting (KM) ........................................ 20-509
[15E7KM] R to 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: Disconnection or short circuit (KZ) .................................. 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

(10)
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

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

a For details of this page, see page 90-19.
HD465-7, HD605-7 20-503

(2)

★ The following information is summarized in the troubleshooting table and the related electrical circuit dia-
panel panel panel
Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble
Problem that
appears on machine

1
• Disconnection
• Ground fault
• Short circuit
indicate priority)
Insert or connect T-adapter as explained below for troubleshooting,
side.
side.
5
side.
20-504 HD465-7, HD605-7

(10)
TROUBLESHOOTING PHENOMENON CODE TABLE






MW Sliding
NS Overheat
HD465-7, HD605-7 20-505

(10)
TROUBLESHOOTING [1380MW]
[1380MW] LOCKUP CLUTCH: SLIP (MW)
Action code Failure 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) (1) – (2) Resistance 5 – 15 z
Between CN20 (male) (1), (2) – chassis ground Resistance Min. 1 Mz
2) Disconnect connector ATC2 and CN10.
Disconnection in wiring har- 3) Connect T-adapter.
Possible causes ness
and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) – Resistance Max. 1 z
in normal state CN20 (female) (1)
contact)
Wiring harness between ATC2 (female) (20) –
Resistance Max. 1 z
CN20 (female) (2)
Defective sensing by speed
3 • Troubleshooting by the failure codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC2.
Transmission controller de- 3) Connect T-adapter.
4
fective
Resistance 5 – 15 z
ATC2 (female) (20)
20-506 HD465-7, HD605-7

(10)
TROUBLESHOOTING [1500L0]
[1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0)

Trouble Detection of double engagement: *See separate list (L0)
E03 1500L0 TM
Contents of trouble • The fill switch signals of abnormally combined 2 clutches are input.
Action of controller • The gear is set in Neutral during travel and the machine cannot start again.
Problem that • The transmission cutout relay is turned OFF.
appears on machine • The gear is set in Neutral.
• Another failure (Clutch pressure control valve system failure code: 15S*L1) occurs simultaneously with
Related information
this failure.

Clutch pressure control
Possible causes
1 valve system failure code • Perform troubleshooting by the indicated failure code.
and standard value
(15S*L1) is indicated.
in normal state
Transmission controller de-
2 • Perform troubleshooting by the indicated failure code.
fective
HD465-7, HD605-7 20-507

(10)
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, TMF and CN10.
Transmission filter clogging 3) Connect T-adapter.
2
sensor defective
Between TMF (male) Filter is normal. Resistance Max. 1 z
(1) – (2) Filter is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC5A, TNF, and CN10.
Possible causes Disconnection in wiring har- 3) Connect T-adapter.
and standard value ness
in normal state 3 Wiring harness between ATC5A (female) (6) –
(Disconnection or defective Resistance Max. 1 z
TMF (female) (1)
contact)
Wiring harness between CJH1 (female) (5) –
Resistance Max. 1 z
TMF (female) (2)
2) Disconnect connectors ATC5A and ATC3A.
Transmission controller de- 4) Connect conector.
4
Between ATC5A (6) – Filter is normal. Voltage Max. 1 V
chassis ground Filter is clogged. Voltage 20 – 30 V
20-508 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15E0KM], [15E7KM]
[15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM)

Trouble R to F gear shift abuse 1: Mistake in operation or setting (KM)
Not set 15E0KM TM
• When the output shaft speed is 200 rpm – 300 rpm (approx. 5 – 7 km/h), the gear is shifted from reverse
Contents of trouble
to forward.
Problem that • If the machine is used without repairing, it may be broken.
appears on machine • The failure is only recorded in the failure history.
Related information • This failure can be checked in the monitoring function (Code: 31400).

and standard value
in normal state 1 Abuse • Change the travel direction after the machine is stopped perfectly.
[15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM)

Trouble R to F gear shift abuse 2: Mistake in operation or setting (KM)
Not set 15E7KM TM
• When the output shaft speed is above 300 rpm (approx. 7 km/h), the gear is shifted from reverse to
Contents of trouble
forward.
Problem that • If the machine is used without repairing, it may be broken.
appears on machine • The failure is only recorded in the failure history.

and standard value
in normal state 1 Abuse • Change the travel direction after the machine is stopped perfectly.
HD465-7, HD605-7 20-509

(10)
TROUBLESHOOTING [15G0MW]
[15G0MW] R CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN10 (female) (2)
sensor
4
fective
ATC2 (female) (15)
20-510 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15H0MW]
[15H0MW] HI CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN18 (female) (2)
sensor
4
fective
ATC2 (female) (19)
HD465-7, HD605-7 20-511

(10)
TROUBLESHOOTING [15H0MW]
20-512 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15J0MW]
[15J0MW] LO CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN16 (female) (2)
sensor
4
fective
ATC2 (female) (17)
HD465-7, HD605-7 20-513

(10)
TROUBLESHOOTING [15J0MW]
20-514 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15K0MW]
[15K0MW] 1ST CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN6 (female) (2)
sensor
4
fective
ATC2 (female) (13)
HD465-7, HD605-7 20-515

(10)
TROUBLESHOOTING [15L0MW]
[15L0MW] 2ND CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN8 (female) (2)
sensor
4
fective
ATC2 (female) (15)
20-516 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15M0MW]
[15M0MW] 3RD CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN12 (female) (2)
sensor
4
fective
ATC2 (female) (18)
HD465-7, HD605-7 20-517

(10)
TROUBLESHOOTING [15N0MW]
[15N0MW] 4TH CLUTCH: SLIP (MW)
Action code Failure 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 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN14 (female) (2)
sensor
4
fective
ATC2 (female) (13)
20-518 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SBL1]
[15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure 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) (1) – chas- engaged
sis ground When en-
Resistance Max. 1 z
gaged
2) Disconnect connectors ATC5A and CN11.
Possible causes
and standard value Ground fault in wiring har-
in normal state 2 Resistance between
ness
Wiring harness between ATC5A ATC5A (female) (16),
Min. 1 Mz
(female) (16) – CN11 (female) (1) CN11 (female) (1) –
chassis ground
3 When dis-
fective Resistance Min. 1 Mz
Between ATC5A (female) (16) – engaged
chassis ground When en-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-519

(10)
TROUBLESHOOTING [15SBMA]
[15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure 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

contact)
Resistance Max. 1 z
CN10 (female) (2)
sensor
4
fective
ATC2 (female) (15)
20-520 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SCL1]
[15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code Failure 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-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-521

(10)
TROUBLESHOOTING [15SCMA]
[15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA)

Action code Failure 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

and standard value 2 (Disconnection or defective
Resistance Max. 1 z
contact)
Resistance Max. 1 z
CN18 (female) (2)
sensor
4
fective
ATC2 (female) (19)
20-522 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SDL1]
[15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code Failure 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-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-523

(10)
TROUBLESHOOTING [15SDMA]
[15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA)

Action code Failure 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

Resistance Max. 1 z
contact)
Resistance Max. 1 z
CN16 (female) (2)
sensor
4
fective
ATC2 (female) (17)
20-524 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SEL1]
[15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure 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) (1) – chassis engaged
ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-525

(10)
TROUBLESHOOTING [15SEMA]
[15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure 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

2) Disconnect connector ATC2 – CN6.
contact)
Resistance Max. 1 z
CN6 (female) (2)
sensor
4
fective
ATC2 (female) (13)
20-526 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SFL1]
[15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure 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-
ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-527

(10)
TROUBLESHOOTING [15SFMA]
[15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure 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

Between CN8 (male)(1) , (2) – chassis ground Resistance Min. 1 Mz
contact)
Resistance Max. 1 z
CN8 (female) (2)
sensor
4
fective
ATC2 (female) (15)
20-528 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SGL1]
[15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure 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-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-529

(10)
TROUBLESHOOTING [15SGMA]
[15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure 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

contact)
Resistance Max. 1 z
CN12 (female) (2)
sensor
4
fective
ATC2 (female) (18)
20-530 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SHL1]
[15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure 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-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-531

(10)
TROUBLESHOOTING [15SHMA]
[15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure 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

contact)
Resistance Max. 1 z
CN14 (female) (2)
sensor
4
fective
ATC2 (female) (13)
20-532 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SJL1]
[15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1)
Action code Failure 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-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-533

(10)
TROUBLESHOOTING [15SJMA]
[15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA)
Action code Failure 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
2) Disconnect connector ATC5A and CN20.
contact)
Resistance Max. 1 z
CN20 (female) (2)
sensor
4
fective
ATC2 (female) (20)
20-534 HD465-7, HD605-7

(10)
TROUBLESHOOTING [2F00KM]
[2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM)
Action code Failure code Controller code Parking brake: Mistake in operation or setting (KM)
Trouble
Not set 2F00KM TM (Parking brake drags)
• When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency brake
Contents of trouble
is operated.
Problem that
• If the machine is used without repairing, it may be broken.
appears on machine

• Set the parking brake switch in the FREE position and then start the
Mistake in operation of park- machine.
1
ing brake switch • Stop the machine perfectly, and then set the emergency brake switch
in the FREE position and start the machine.
Relay
Yes
When the parking brake relay (R03) is re- (R03)
placed, is failure repaired? Relay
No
(R03)
Parking brake relay (R03) 3) Check the relay.
2
defective Between R03 (male) (1) – (2) Resistance 200 – 400 z
in normal state
Apply 24 V between
(3) – (6) Do not apply 24 V be-
Resistance Max. 1 z
tween (1) – (2).
2) Disconnect connector PSW.
Parking brake oil pressure Set parking brake
3
switch defective switch in FREE posi- Resistance Min. 1 Mz
Between PSW (male) position.
(1) – (2) Set parking brake
switch in PARK posi- Resistance Max. 1 z
tion.
Mistake in operation of
emergency brake
4 • Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
HD465-7, HD605-7 20-535

(10)
TROUBLESHOOTING [2F00KM]

Wiring harness between R03 (female) (2), (6) –
Resistance Max. 1 z
Disconnection in wiring har- chassis ground
ness 1) Turn the starting switch OFF.
5
(Disconnection or defective 2) Disconnect connectors R03, BT3, and PSW.
contact) 3) Connect T-adapter.
Wiring harness between fuse BT3 (16) – PSW
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
PSW (female) (2)
and standard value 2) Disconnect connectors BRC5A and R03.
in normal state Ground fault of wiring har- 3) Connect T-adapter.
6
ness
Between BRC5A (female), R03 (female) (3) –
chassis ground
2) Disconnect connector BRC5A.
4) Connect connector BRC5A
7 Retarder controller defective Set parking brake
switch in FREE posi- Voltage Max. 1 V
Between BRC5A (5) – tion.
chassis ground Set parking brake
switch in PARK posi- Voltage 20 – 30 V
tion.
20-536 HD465-7, HD605-7

(10)
TROUBLESHOOTING [989A00]
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00)

Trouble Engine overrun prevention command signal: Operation (00)
E02 989A00 TM
• When the gear speed is not in neutral, the transmission input shaft speed signal rises higher than 2,600
Contents of trouble
rpm.
Action of controller • The controller sends a command signal to the retarder controller to apply the brake.
Problem that
• The brake operates and the travel speed lowers.
appears on machine

aIf the machine is traveling under the condition where the transmission
Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2,600 rpm, the engine is
and standard value overrunning.
in normal state • If the machine is not traveling under the condition where the transmis-
2 sion input shaft speed signal rises higher than 2,600 rpm, the trans-
fective
mission controller is defective.
HD465-7, HD605-7 20-537

(10)
TROUBLESHOOTING [989AKZ]
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION

OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code Engine overrun prevention command signal: Disconnection or
Trouble
E01 989AKZ TM short circuit (KZ)
• There is disconnection, grounding fault, or short circuit with power source in the engine overrun pre-
Contents of trouble
vention command signal circuit.
Action of controller • The controller continues the control with the S-NET signal.
Problem that
• This failure does not have a serious effect on the machine.
appears on machine
Related information • None in particular.

2) Disconnect connectors ATC1 and BRC5B.
ness
1 Wiring harness between ATC1 (female) (13) –
BRC5B (female) (5)
contact)
Wiring harness between fuse BT3 Voltage between ATC1
20 – 30 V
terminal (14) – ATC1 (female) (4) (4) – chassis ground
2) Disconnect connectors ATC1 – BRC5B.
Ground fault of wiring har-
2 Resistance between
ness
Wiring harness between ATC1 (fe- ATC1 (female) (13),
Min. 1 Mz
male) (13) – BRC5B (female) (5) BRC5B (female) (5) –
chassis ground
and standard value 2) Disconnect connectors ATC1 – BRC5B.
in normal state 3) Connect T-adapter.
3 Hot short in wiring harness Voltage between ATC1
Wiring harness between ATC1
(female) (13), BRC5B
(female) (13) – BRC5B (female) Max. 1 V
(female) (5) – chassis
(5)
ground
2) Disconnect connector BRC5B.
4 Retarder controller defective 4) Connect the connector.
Between BRC5B (5) – chassis ground Voltage Max. 1 V
5 4) Connect the connector.
fective
Between ATC1 (13) – chassis ground Voltage Max. 1 V
20-538 HD465-7, HD605-7

(10)
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

The dust indicator is not red. Air cleaner is normal.
1 Clogging of air cleaner
The dust indicator is red. Air cleaner is clogged.
Relay (R32)
No
When the dust indicator relay (R32) is re- is normal.
placed, is failure repaired? Relay (R32)
Yes
is defective.
Dust indicator relay (R32) 3) Check the relay.
2
defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Possible causes
2) Disconnect connectors FR01.
and standard value Air cleaner clogging sensor 3) Connect T-adapter.
in normal state 3
defective
Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z
(1) – (2) Air cleaner is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and R32.
ness
4 Wiring harness between ATC3A (female) (16)
– R32 (female) (6)
contact)
Wiring harness between ATC3A (female) (19)
Resistance Max. 1 z
– R32 (female) (3)
2) Disconnect connector R32 and FR01.
Ground fault of wiring har-
ness
Wiring harness between R32 R32 (female) (2),
Min. 1 Mz
(female) (2) – FR01 (female) (1) FR01 (female) (1)–
chassis ground
2) Disconnect connectors ATC3A.
Transmission controller de- 4) Connect connector.
6
Between ATC3A (19) Air cleaner is normal. Voltage 20 – 30 V
– (16) Air cleaner is clogged. Voltage Max. 1 V
HD465-7, HD605-7 20-539

(10)
TROUBLESHOOTING [AA10NX]
20-540 HD465-7, HD605-7

(1)
TROUBLESHOOTING [AB00MA]
[AB00MA] ALTERNATOR: MALFUNCTION (MA)
Action code Failure 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 – E Voltage 20 – 30 V
aIf the battery is deteriorated or used in a cold district, the voltage may
not rise for a while after the engine is started.
2) Disconnect connector ATC3B.
Disconnection in wiring har- Wiring harness between Voltage between ATC3B (fe-
20 – 30 V
Possible causes ness ATC3B (female) (1) – alter- male) (1) – chassis ground
and standard value 2 (Disconnection or defective nator terminal R Resistance Max. 1 z
in normal state contact) aIf the battery is deteriorated or used in a cold district, the voltage may
Wiring harness between battery relay terminal
Resistance Max. 1 z
M – alternator terminal R
3 5) Start the engine.
fective
Between ATC3B (1) – chassis ground Voltage 20 – 30 V
aIf the battery is deteriorated or used in a cold district, the voltage may
HD465-7, HD605-7 20-541

(10)
TROUBLESHOOTING [AB00MA]
20-542 HD465-7, HD605-7

(1)
TROUBLESHOOTING [B@BCZK]
[B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK)

Trouble Lowering of radiator coolant: Lowering of level (ZK)
E01 B@BCZK TM
Contents of trouble • The radiator coolant level switch signal circuit is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, the engine may overheat.
appears on machine

• The radiator coolant level is normal.
Lowering of radiator coolant
1
level aIf the radiator coolant level is low, check around the engine and ra-
diator for coolant leakage before adding coolant .
2) Disconnect connector FL01.
Radiator coolant level
2 Radiator coolant level
switch defective Resistance Max. 1 z
Between FL01 (male) is normal.
(1) – (2) Radiator coolant level
is low.
Possible causes 2) Disconnect connectors ATC5A and FL01.
and standard value Disconnection in wiring har- 3) Connect T-adapter.
in normal state ness
3 Wiring harness between ATC5A (female) (3) –
FL01 (female) (1)
contact)
Wiring harness between FL01 (female) (2) –
Resistance Max. 1 z
chassis ground
Transmission controller de- 5) Turn the starting switch ON.
3
fective
Radiator coolant level
Between ATC5A (fe- is normal. Voltage Max. 1 V
male) (3) – chassis
ground Radiator coolant level
Voltage 20 – 30 V
is low.
HD465-7, HD605-7 20-543

(10)
TROUBLESHOOTING [D1B0KZ]
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT

CIRCUIT (KZ)
Action code Failure code Controller code Transmission controller cutout relay: Disconnection or short cir-
Trouble cuit (KZ)
E03 D1B0KZ TM (Disconnection or short circuit)
Contents of trouble • Abnormal voltage is generated in the transmission cutout relay circuit.
• The controller turns the transmission cutout relay OFF.
• The controller sets the gear in Neutral.
Problem that
appears on machine

Relay (R15)
No
When transmission cutout relay (R15) is is normal.
replaced, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay (R15) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
between (1) – (2).
and standard value 2) Disconnect connectors ATC1 and R15.
ness Wiring harness between ATC1 (female) (14) –
2 Resistance Max. 1 z
(Disconnection or defective R15 (female) (1)
contact) Between R15 (female) (2) – chassis ground Resistance Max. 1 z
Wiring harness between fuse BT2 Voltage between ATC1
20 – 30 V
terminal (22) – ATC1 (female) (5) (5) – chassis ground
2) Disconnect connectors ATC1 and R15.
Ground fault in wiring har-
ness
Min. 1 Mz
male) (14) – R15 (female) (1) R15 (female) (1) –
chassis ground
4
fective When failure code to turn transmis-
Between sion cutout relay OFF is displayed Voltage Max. 1 V
ATC1 (14) (Example: 1500LO)
– (8), (16)
When failure code is not displayed Voltage 20 – 30 V
20-544 HD465-7, HD605-7

(10)
TROUBLESHOOTING [D1BOKZ]
HD465-7, HD605-7 20-545

(1)
TROUBLESHOOTING [D5ZMKZ]
[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE

OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT
(KZ)
Action code Failure code Controller code Disconnection, grounding fault, or short circuit in engine output
Trouble
E01 D5ZMKZ TM mode command line: Disconnection or short circuit (KZ)
Contents of trouble • Disconnection, grounding fault, or short circuit occurs in engine output mode command line.
Action of controller • The controller controls in the power mode (The machine is fixed to the power mode).
Problem that
appears on machine

Disconnection in wiring har- 2) Disconnect connectors ATC1 – ECMB.
1
ECMB (female) (19)
2) Disconnect connectors ATC1 and ECMB.
2
ness Wiring harness between Resistance between ATC1
ATC1 (female) (15) – ECMB (female) (15), ECMB (fe- Min. 1 Mz
(female) (19) male) (19) – chassis ground
2) Disconnect connectors ATC5A and BRC5B.
3 Hot short in wiring harness 3) Connect T-adapter.
Possible causes
and standard value Between ATC1 (female) (15), ECMB (female)
Voltage Max. 1 V
in normal state (19) – chassis ground
Between ECMB (19) – In power mode Voltage 9.4 – 12 V
chassis ground In economy mode Voltage 0 – 2.4 V
Transmission controller de- 4) Disconnect the connector.
5
fective 5) Start the engine.
Between ATC1 (15) – In power mode Voltage 9.4 – 12 V
chassis ground
In economy mode Voltage 0 – 2.4 V
20-546 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQ0KK]
[DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE

(KK)

Trouble Transmission controller: Lowering of source/input voltage (KK)
E03 DAQ0KK TM
• While the engine is running, the voltages of both main power source voltage circuit and direct power
Contents of trouble
source voltage circuit lower below 18 V.
Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage
appears on machine rises to the normal level.
• If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), and (17) for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Battery defective
Specific
Specific gravity of battery fluid Min. 1.26
gravity
Wiring harness between ATC1 (female) (8),
Resistance Max. 1 z
(16) – chassis ground
ness 4) Connect the connector.
2
(Disconnection or defective Wiring harness between battery, Voltage between ATC1
contact) 20 – 30 V
Possible causes battery relay terminal B, – ATC1 (7) (7) – (8), (16)
in normal state 2) Disconnect connector ATC1.
Wiring harness between battery re- Voltage between ATC1
20 – 30 V
lay terminal M – ATC1 (9), (17) (9), (17) – (8), (16)
2) Disconnect connector ATC1
Between ATC1 (7) – (8), (16) Voltage 20 – 30 V
3 1) Turn the starting switch OFF.
fective
2) Disconnect connector ATC1
Between ATC1 (9), (17) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-547

(10)
20-548 HD465-7, HD605-7

(1)
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF

SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Main power line of transmission controller: Lowering of source/in-
Trouble
E03 DAQ1KK TM put voltage (KK)
Contents of trouble • The main power source voltage is lower than the direct power source voltage by 5 V or more.
Action of controller • The controller prohibits updating of information about input.
Problem that
• The condition before the failure is kept.
appears on machine
Related information • If the fuse is broken, check the line between the fuse – ATC1 (female) (9) and (17) for grounding fault.

Resistance Max. 1 z
Disconnection in wiring har- 4) Connect the connector.
ness
1
(Disconnection or defective Wiring harness between battery – Voltage between bat-
contact) tery relay terminal B – 20 – 30 V
Possible causes battery relay terminal B
chassis ground
and standard value
Wiring harness between battery re- Voltage between ATC1
20 – 30 V
lay terminal M – ATC1 (9), (17) (9), (17) – (8), (16)
Transmission controller de- 3) Insert T-adapter.
fective
Between ATC1 (9), (17) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-549

(10)
20-550 HD465-7, HD605-7

(1)
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF

Action code Failure code Controller code Transmission controller load power line: Lowering of source/input
Trouble
E03 DAQ2KK TM voltage (KK)
Contents of trouble • While the transmission controller source voltage is normal, the solenoid source voltage is below 18 V.
• The controller sets the gear in Neutral.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) (9) and (17) for grounding fault.

3) Turn the starting switch ON
Relay (R15)
No
When transmission cutout relay (R15) is re- is normal.
placed, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay (R15) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Possible causes
and standard value (3) – (5) Do not apply voltage
in normal state between (1) – (2).
2) Disconnect connectors R15.
Disconnection in wiring har- Wiring harness between fuse BT3 Voltage between R15
ness (female) (3) – chassis 20 – 30 V
2 to 14 – R15 (female) (3)
(Disconnection or defective ground
contact) 1) Turn the starting switch OFF.
2) Disconnect connectors ATC2 and R15.
Wiring harness between ATC2 (1), (12) – R15
Resistance Max. 1 z
(female) (3)
fective
Between ATC2 (1), (12) – chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-551

(10)
20-552 HD465-7, HD605-7

(1)
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING

OF SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Direct line of transmission controller battery: Lowering of source/
Trouble
E03 DAQ3KK TM input voltage (KK)
Contents of trouble • The direct power source voltage is below 5 V.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) (7) for grounding fault.

Disconnection in wiring har- (16) – chassis ground Resistance Max. 1 z
ness
1
(Disconnection or defective 1) Turn the starting switch OFF.
contact) 2) Disconnect connector ATC1.
Possible causes
and standard value
in normal state
Wiring harness between battery, Voltage between ATC1
20 – 30 V
battery relay terminal B, – ATC1 (7) (7) – (8), (16)
fective
Between ATC1 (7) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-553

(10)
TROUBLESHOOTING [DAQ9KM]
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN

OPERATION OR SETTING (KM)
Action code Failure code Controller code Transmission controller wiring harness: Mistake in operation or
Trouble
E03 DAQ9KM TM setting (KM)
• The connector check signal, that is input when the starting switch is turned to the ON position, does not
Contents of trouble
agree with setting in the controller.
Action of controller • The controller keeps the gear speed in neutral.
• This failure is not recorded in the fault history.
Problem that
• When the starting operation is performed, the machine does not start.
appears on machine

The connector of the connector check signal is connected normally.
Wrong connection of con-
1 aConnector check signal connector: ATC3A (1) (OPEN), ATC5A (1)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector ATC5A.
2
Wiring harness between ATC5A (female) (1) –
chassis ground
and standard value 2) Disconnect connector ATC3A.
in normal state Ground fault in wiring har- 3) Connect T-adapter.
3
ness Resistance between
Wiring harness between ATC3A
ATC3A (female) (1) – Min. 1 Mz
(female) (1) – chassis ground
chassis ground
4
fective Wiring harness between ATC5A (female) (1) –
Resistance Max. 1 z
chassis ground
Between ATC3A (female) (1) – chassis ground Resistance Min. 1 Mz
20-554 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQ9KQ]
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF

MODEL SELECTION SIGNALS (KQ)
Action code Failure code Controller code Transmission controller wiring harness: Disagreement of model
Trouble
E03 DAQ9KQ TM selection signals (KQ)
• The model selection signal input when the starting switch is turned ON is different from the setting of
Contents of trouble
the controller.
Action of controller • The controller sets the gear speed in neutral.
Problem that
appears on machine

ness
chassis ground
contact)
Resistance Max. 1 z
chassis ground
Possible causes 3) Connect T-adapter.
and standard value 2 ness Resistance between
in normal state Wiring harness between ATC5A ATC5A (female) (15),
Min. 1 Mz
(female) (15) – MS21 (female) MS21 (female) – chas-
sis ground
Wrong setting of rotary • For setting of the rotary switch, see ADJUSTING TRANSMISSION
3
switch CONTROLLER.
Wrong setting of rotary
4 Between ATC5A (female) (14) – chassis ground Resistance Max. 1 z
switch
Between ATC5A (female) (15) – chassis ground Resistance Min. 1 Mz
Between ATC5A (female) (16) – chassis ground Resistance Max. 1 z
HD465-7, HD605-7 20-555

(10)
TROUBLESHOOTING [DAQAKQ], [DAQSMA]
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF

Action code Failure code Controller code Transmission controller wiring harness: Disagreement of model
Trouble
E03 DAQAKQ TM selection signals (KQ)
Contents of trouble • Setting of the model by the rotary switch does not agree with setting in the controller.
Action of controller • The controller sets the gear speed in neutral.
Problem that
appears on machine

Wrong setting of rotary • For setting of the rotary switch, see ADJUSTING TRANSMISSION
Possible causes 1
switch CONTROLLER.
and standard value
in normal state • For setting of the rotary switch, see ADJUSTING TRANSMISSION
2 CONTROLLER.
fective
aIf setting is normal, the transmission controller is defective.
[DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA)

Trouble Transmission controller: Malfunction (MA)
E03 DAQSMA TM
Contents of trouble • Communication with the machine monitor (S-NET) is defective and the optional items cannot be set.
Action of controller • The controller sets the gear speed in Neutral.
Problem that
appears on machine
• If failure code "DAQSKR" of the machine monitor system is indicated, perform troubleshooting for it
first.
Related information
• Do not turn the starting switch to the left before starting the engine (Since the engine preheating system
is automatic, the starting switch does not need to be turned to the left).

Possible causes aIf the failure is not repaired by replacing the transmission controller,
1 Machine monitor defective
and standard value the machine monitor is defective.
in normal state Transmission controller de- aIf the failure is repaired by replacing the transmission controller, the
2
fective transmission controller is defective.
20-556 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTGKA]
[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Lockup clutch fill switch: Disconnection (KA)
Trouble (Command is Holding pressure, fill switch is OFF, and slip is not
E03 DDTGKA TM sensed)
• When the output to the lockup clutch ECMV 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.
• 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.
appears on machine
• The lockup pilot lamp does not light up.

Lockup clutch fill switch de-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21.
2 3) Connect T-adapter.
in normal state (Disconnection or defective
– CN21 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-557

(10)
TROUBLESHOOTING [DDTHKA]
[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Hi clutch fill switch: Disconnection (KA)
E03 DDTHKA TM sensed)
• When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble
switch is not turned ON.
Problem that • The gear cannot be shifted.

1 Hi clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN19.
CN19 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-558 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTJKA]
[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Lo clutch fill switch: Disconnection (KA)
E03 DDTJKA TM sensed)
• When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 Lo clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN17.
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-559

(10)
TROUBLESHOOTING [DDTKKA]
[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 1st clutch fill switch: Disconnection (KA)
E03 DDTKKA TM sensed)
• When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 1st clutch fill switch defective When dis-
ground When en-
Resistance Max. 1 z
gaged
3 When dis-
Resistance Max. 1 z
gaged
20-560 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTLKA]
[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 2nd clutch fill switch: Disconnection (KA)
E03 DDTLKA TM sensed)
• When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.

2nd clutch fill switch defec-
1 When dis-
ground When en-
Resistance Max. 1 z
gaged
CN9 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-561

(10)
TROUBLESHOOTING [DDTMKA]
[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 3rd clutch fill switch: Disconnection (KA)
E03 DDTMKA TM sensed)
• When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

3rd clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN13 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-562 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTNKA]
[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code R clutch fill switch: Disconnection (KA)
E03 DDTNKA TM sensed)
• When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 R clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN11 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-563

(10)
TROUBLESHOOTING [DDTPKA]
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA)
Action code Failure code Controller code 4th clutch fill switch : Disconnection (KA)
E03 DDTPKA TM sensed)
• When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

4th clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN15 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-564 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DF10KA]
[DF10KA] SHIFT LEVER: DISCONNECTION (KA)

Trouble Shift lever: Disconnection (KA)
E03 DF10KA TM
Contents of trouble • The shift lever signal is not input at all.
Action of controller • The controller keeps the condition before occurrence of the failure..
• The gear may be shifted up above the gear speed set with the shift lever.
Problem that • The gear is kept in neutral and the machine cannot start.
appears on machine • The travel direction cannot be changed.
• All the shift lever position lamps go off.

• The shift lever is pressed by some force while it is not operated.
1 Wrong operation
• The shift lever is stopped between 2 positions.
2) Disconnect connector SF1.
Wiring harness between BT3 (10) – SF1 (fe-
Resistance Max. 1 z
male) (1)
2) Disconnect connectors ATC5B and SF1.
Wiring harness between ATC5B (female) (2) –
Resistance Max. 1 z
SF1 (female) (3)
Resistance Max. 1 z
Disconnection in wiring har- SF1 (female) (4)
ness Wiring harness between ATC5B (female) (4) –
2 (Disconnection or defective SF1 (female) (5) Resistance Max. 1 z
contact of connector)
Resistance Max. 1 z
SF1 (female) (6)
Resistance Max. 1 z
Possible causes SF1 (female) (7)
and standard value Wiring harness between ATC5B (female) (7) –
SF1 (female) (8)
Resistance Max. 1 z
SF1 (female) (9)
Resistance Max. 1 z
SF1 (female) (10)
Resistance Max. 1 z
SF1 (female) (11)
Resistance between
Wiring harness between ATC5B ATC5B (female) (2),
Min. 1 Mz
(female) (2) – SF1 (female) (3) SF1 (female) (3) –
chassis ground
3 Hot short in wiring harness Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
HD465-7, HD605-7 20-565

(10)

Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
and standard value When shift range is "R" Voltage 20 – 30 V
in normal state Between SF1 (3) –
chassis ground When shift range is not
Voltage Max. 1 V
"R"
When shift range is "N" Voltage 20 – 30 V
Between SF1 (4) –
Voltage Max. 1 V
"N"
When shift range is "D" Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
"D"
When shift range is "6" Voltage 20 – 30 V
Between SF1 (6) –
4 Gearshift lever defective Voltage Max. 1 V
"6"
Between SF1 (7) –
Voltage Max. 1 V
"5"
Between SF1 (8) –
Voltage Max. 1 V
"4"
Between SF1 (9) –
Voltage Max. 1 V
"3"
Between SF1 (10) –
Voltage Max. 1 V
"2"
Voltage Max. 1 V
"1"
20-566 HD465-7, HD605-7

(10)

When shift range is "R" Voltage 20 – 30 V
Between ATC5B (2) –
Voltage Max. 1 V
"R"
Voltage Max. 1 V
"N"
When shift range is not
chassis ground Voltage Max. 1 z
"D"
Possible causes Between ATC5B (5) –
and standard value Transmission controller de- chassis ground When shift range is not
5 Voltage Max. 1 V
in normal state fective "6"
Voltage Max. 1 V
"5"
Voltage Max. 1 V
"4"
Voltage Max. 1 V
"3"
Voltage Max. 1 V
"2"
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-567

(10)
20-568 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DF10KB]
[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB)

Trouble Shift lever: Short circuit (KB)
E03 DF10KB TM
Contents of trouble • The shift lever signals are input from 2 or more systems.
• The controller controls with the signal having higher priority.
(1): N > D > 6 > 5 > 4 > 3 > 2 > 1.
(2): N > R
• If the signals of systems (1) and (2) are input simultaneously, the controller sets the gear in neutral.
• The gear may be shifted up above the gear speed set with the shift lever.
Problem that
• The gear is kept in neutral and the machine cannot start.
appears on machine
• The shift lever position lamp is different from the shift lever position.

Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
Possible causes
Short circuit in wiring har- chassis ground
and standard value
in normal state 1 ness Voltage between
(Hot short in wiring harness) Wiring harness between ATC5B ATC5B (female) (6),
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
HD465-7, HD605-7 20-569

(10)

Between SF1 (3) –
Voltage Max. 1 V
"R"
Between SF1 (4) –
Voltage Max. 1 V
"N"
Between SF1 (5) – When shift range is "D" Voltage 20 – 30 V
Voltage Max. 1 z
"D"
Between SF1 (6) –
2 Gearshift lever defective Voltage Max. 1 V
"6"
Between SF1 (7) –
Voltage Max. 1 V
"5"
Between SF1 (8) – When shift range is "4" Voltage 20 – 30 V
Voltage Max. 1 V
"4"
Between SF1 (9) –
Possible causes Voltage Max. 1 V
"3"
and standard value
in normal state Between SF1 (10) –
Voltage Max. 1 V
"2"
Voltage Max. 1 V
"1"
When the right FNR switch is installed (Turn the right FNR switch ON)
Voltage Max. 1 V
"R"
Transmission controller de- Between ATC5B (3) – When shift range is not
3 chassis ground Voltage Max. 1 V
fective "N"
Voltage Max. 1 V
"D"
Between ATC5B (5) – When shift range is "6" Voltage 20 – 30 V
Voltage Max. 1 z
"6"
Voltage Max. 1 V
"5"
20-570 HD465-7, HD605-7

(10)

Voltage Max. 1 V
"4"
Between ATC5B (8) – When shift range is "3" Voltage 20 – 30 V
Possible causes chassis ground When shift range is not
Transmission controller de- Voltage Max. 1 V
and standard value "3"
in normal state 3 fective
Voltage Max. 1 V
"2"
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-571

(10)
TROUBLESHOOTING [DGF1KX]
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT

SIGNAL RANGE (KX)
Action code Failure code Controller code Transmission valve oil temperature sensor: Out of input signal
Trouble
E03 DGF1KX TM range (KX)
• The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0.97 V (above
Contents of trouble
150°C) or very different from the torque converter oil temperature signal.
Action of controller • The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
Problem that
• Gear shift shocks become large.
appears on machine
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".

Transmission oil tempera- 3) Connect T-adapter.
1
ture sensor defective
Between CN24 (male) Oil temperature: 25°C Resistance 37 – 50 kz
(1) – (2) Oil temperature: 100°C Resistance 3.5 – 4.0 kz
2) Disconnect connectors ATC3A, ATC3B, and CN24.
ness
2 Wiring harness between ATC3B (female) (9) –
CN24 (female) (2)
contact)
Resistance Max. 1 z
CN24 (female) (1)
2) Disconnect connectors ATC3B and CN24.
Possible causes 3 Resistance between
ness
and standard value Wiring harness between ATC3B ATC3B (female) (9),
in normal state Min. 1 Mz
chassis ground
Voltage between
Max. 1 V
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
5 5) Turn the starting switch ON.
fective
Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kz
male) (9) – ATC3A (fe-
male) (16) Oil temperature: 100°C Resistance 3.5 – 4.0 kz
20-572 HD465-7, HD605-7

(10)
TROUBLESHOOTING [GDF1KX]
HD465-7, HD605-7 20-573

(1)
TROUBLESHOOTING [DGT1KX]
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF

INPUTSIGNAL RANGE (KX)
Action code Failure code Controller code Torque converter oil temperature sensor: Out of input signal
Trouble
E01 DGT1KX TM range (KX)
• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above
Contents of trouble
150°C) or very different from the transmission valve oil temperature signal.
Problem that
• The torque converter oil temperature gauge does not indicate normally.
appears on machine

Torque converter oil temper- 3) Connect T-adapter.
1
ature sensor defective
Between CN23 (T/C-T) Oil temperature: 25°C Resistance 37 – 50 kz
(male) (1) – (2) Oil temperature: 100°C Resistance 3.5 – 4.0 kz
2) Disconnect connectors ATC3A, ATC3B, and CN23.
ness
2 Wiring harness between ATC3B (female) (7) –
TC-SE (female) (2)
contact)
Resistance Max. 1 z
CN23 (female) (1)
Possible causes Ground fault in wiring har-
in normal state Min. 1 Mz
chassis ground
Voltage between
Max. 1 V
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
5 5) Turn the starting switch ON.
fective
Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kz
male) (7) – ATC3A (fe-
male) (16) Oil temperature: 100°C Resistance 3.5 – 4.0 kz
20-574 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DHT5KX]
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure code Controller code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX TM (KX)
• The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above 4.5
Contents of trouble
V.
Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
• Large shocks are made when the lockup system is operated.
appears on machine

2) Disconnect connectors ATC1, ATC3A and CN22.
Disconnection in wiring har- Wiring harness between ATC3A (female) (7) –
1 CN22 (female) (C)
CN22 (female) (A)
Resistance Max. 1 z
CN22 (female) (B)
Resistance between
Ground fault in wiring har- Min. 1 Mz
2 (female) (7) – CN22 (female) (C) CN22 (female) (C) –
ness
chassis ground
Resistance between
Min. 1 Mz
male) (3) – CN22 (female) (B) CN22 (female) (B) –
Possible causes chassis ground
in normal state 2) Disconnect connectors ATC3B and CN22.
Voltage between
0.8 – 2.0 V
(female) (7) – CN22 (female) (C) CN22 (female) (C) –
chassis ground
Torque converter oil pres- 4) Connect the connector.
4
sure sensor defective 5) Turn the starting switch ON.
Between CN22 (B) – (A) Voltage 20 – 30 V
Between CN22 (C) – (A) Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3A.
5
Between ATC1 (3) – ATC3A (17) Voltage 20 – 30 V
Between ATC3A (7) – (17) Voltage 0.8 – 2.0 V
HD465-7, HD605-7 20-575

(10)
TROUBLESHOOTING [DHT5KX]
20-576 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DHT5L6]
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE SEPARATE LIST

(L6)

Trouble Torque converter oil pressure sensor: *See separate list (L6)
E01 DHT5L6 TM
• While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter
Contents of trouble
oil pressure sensor.
Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
• Large shocks are made when the lockup system is operated.
appears on machine

Voltage between
Max. 1.2 V
(female) (7) – CN22 (female) (C) CN22 (female) (C) –
chassis ground
Possible causes 2) Disconnect connector CN22.
and standard value 3) Insert T-adapter.
Torque converter oil pres- 4) Connect the connector.
in normal state 2
Between CN22 (B) – (A) Voltage 20 – 30 V
Between CN22 (C) – (A) Voltage 0.8 – 2.0 V
3
Between ATC1 (3) – ATC3A (17) Voltage 20 – 30 V
HD465-7, HD605-7 20-577

(10)
TROUBLESHOOTING [DJF1KA]
[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA)

Trouble Fuel level sensor: Disconnection (KA)
E01 DJF1KA TM
Contents of trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Problem that
• The fuel level gauge does not indicate normally.
appears on machine

2) Disconnect connector T01.
1 Fuel level sensor defective 3) Connect T-adapter.
Between T01 Fuel level: When FULL Resistance Max. 12 z
(female) (1) – (2) Fuel level: When EMPTY Resistance 74 – 100 z
Disconnection in wiring har- 2) Disconnect connectors ATC3A, ATC3B, and T01.
2 (Disconnection or defective Wiring harness between ATC3B (female) (4) –
Resistance Max. 1 z
contact) T01 (female) (1)
Resistance Max. 1 z
T01 (female) (2)
and standard value 2) Disconnect connectors ATC3B and T01.
in normal state 3) Insert T-adapter.
4) Turn the starting switch ON..
Voltage between
Max. 1 V
(female) (4) – T01 (female) (1) T01 (female) (1) –
chassis ground
4
fective
Between ATC3B Fuel level: When FULL Resistance Max. 12 z
(female) (3) –
ATC3A (female) Fuel level: When EMPTY Resistance 74 – 100 z
(16)
20-578 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DK11KX]
[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Throttle angle sensor: Out of input signal range (KX)
E03 DK11KX TM
• The voltage of the signal circuit of the acceleration sensor for transmission control is below 0.6 V or
Contents of trouble
above 4.7 V.
• The controller controls the machine, assuming that the engine is at full throttle. (This is not related to
the engine control, however.)
Problem that • Gear shift shocks become large.
appears on machine • The gear is shifted up soon when the machine travels down a slope with the brake OFF.

2) Disconnect connectors ATC3A, ATC3B, and AS2.
Disconnection in wiring har- Wiring harness between ATC3B (female) (11) –
1 AS2 (female) (2)
AS2 (female) (3)
Resistance Max. 1 z
AS2 (female) (1)
2) Disconnect connectors ATC3A, ATC3B, and AS2.
Resistance between
Ground fault in wiring har- Min. 1 Mz
2 (female) (6) – AS2 (female) (1) AS2 (female) (1) –
ness
chassis ground
Resistance between
Min. 1 Mz
(female) (11) – AS2 (female) (2) AS2 (female) (2) –
in normal state 2) Disconnect connectors ATC3B and AS2.
Voltage between
Max. 1 V
(female) (11) – AS2 (female) (2) AS2 (female) (2) –
chassis ground
Acceleration sensor defec- 4) Connect the connector.
4
tive 5) Turn the starting switch ON.
Between AS2 (1) – (3) Voltage 4.6 – 5.4 V
Between AS2 (2) – (3) Voltage 1.0 – 4.0 V
5
Between ATC3B (11) – ATC3A (16) Voltage 1.0 – 4.0 V
HD465-7, HD605-7 20-579

(10)
20-580 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DLE2KA]
[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA)

Trouble Engine speed sensor: Disconnection (KA)
E03 DLE2KA TM
Contents of trouble • The signal circuit of the engine speed sensor is disconnected and signals are not input.
• 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.
appears on machine
• The tachometer does not operate (but indicates 0 rpm).

• Press the sensor lightly against the flywheel ring gear, and then re-
Wrong adjustment of engine turn it by 1/2 – 3/4 turns.
1
speed sensor aFor details, see TESTING AND ADJUSTING, "Adjustment of en-
gine speed sensor".
2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
2
tive
Between E03 (male) (1) – (2) Resistance 500 – 1,000 z
Possible causes Between E03 (male) (1), (2) – chassis ground Resistance Min. 1 Mz
in normal state 2) Disconnect connectors ATC3A – E03.
ness
E03 (female) (1)
contact)
Resistance Max. 1 z
E03 (female) (2)
Transmission controller de- 2) Disconnect connector ATC3A.
fective
Between ATC3A (female) (13) – (14) Resistance 500 – 1,000 z
HD465-7, HD605-7 20-581

(10)
TROUBLESHOOTING [DLE2LC]
[DLE2LC] ENGINE SPEED SENSOR: *SEE SEPARATE LIST (LC)

Trouble Engine speed sensor: *See separate list (LC)
E01 DLE2LC TM
• When the engine speed sensor signal is below 350 rpm, the input transmission input shaft speed sen-
Contents of trouble
sor signal is above 500 rpm.

2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
1
tive
Between E03 (male) (1) – (2) Resistance 500 – 1,000 z
Between E03 (male) (1), (2) – chassis ground Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and E03.
ness
Possible causes Min. 1 Mz
(female) (13) – E03 (female) (1) E03 (female) (1) –
and standard value chassis ground
in normal state
2) Disconnect connectors ATC3A and E03.
Voltage between
Max. 1 V
(female) (13) – E03 (female) (1) E03 (female) (1) –
chassis ground
fective
20-582 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLF1KA]
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission input shaft speed sensor: Disconnection (KA)
E03 DLF1KA TM
• The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not in-
Contents of trouble
put.
Problem that • The lockup system is reset and the gear cannot be shifted.

• Press the sensor lightly against the revolution pickup gear, and then
Wrong adjustment of trans-
return it by 1/2 – 1 turn.
1 mission input shaft speed
aFor details, see TESTING AND ADJUSTING, "Adjustment of trans-
sensor
mission speed sensor".
Transmission input shaft 3) Connect T-adapter.
2
speed sensor defective
Between CN3 (male) (1) – (2) Resistance 500 – 1,000 z
Possible causes Between CN3 (male) (1), (2) – chassis ground Resistance Min. 1 Mz
in normal state 2) Disconnect connectors ATC3A and CN3.
ness
CN3 (female) (1)
contact)
Resistance Max. 1 z
CN3 (female) (2)
fective
HD465-7, HD605-7 20-583

(10)
TROUBLESHOOTING [DLF1LC]
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)

Trouble Transmission input shaft speed sensor: *See separate list (LC)
E03 DLF1LC TM
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sen-
Contents of trouble sor signal, and transmission output shaft speed sensor signal is different from the signal speed of the
transmission input shaft speed sensor.

Transmission input shaft 3) Connect T-adapter.
1
ness
in normal state
Voltage between
Max. 1 V
chassis ground
fective
20-584 HD465-7, HD605-7

(10)
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION

(KA)
Action code Failure code Controller code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA TM (KA)
• The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are
Contents of trouble
not input.

1 mission intermediate shaft
speed sensor
Transmission intermediate 2) Disconnect connector CN4.
2 shaft speed sensor defective 3) Connect T-adapter.
in normal state 2) Disconnect connectors ATC3A – CN4.
ness
CN4 (female) (1)
contact)
Resistance Max. 1 z
fective
HD465-7, HD605-7 20-585

(10)
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:

*SEE SEPARATE LIST (LC)
Action code Failure code Controller code Transmission intermediate shaft speed sensor: *See separate list
Trouble
E03 DLF2LC TM (LC)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission output shaft speed sensor signal is different from the signal speed of the trans-
mission intermediate shaft speed sensor.

Transmission intermediate 3) Connect T-adapter.
1
shaft speed sensor defective
2) Disconnect connectors ATC3A – CN4.
ness
in normal state
Voltage between
Max. 1 V
chassis ground
fective
20-586 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLT3KA]
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission output shaft speed sensor: Disconnection (KA)
E03 DLT3KA TM
• The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
Contents of trouble
input.
appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral

return it by 1/2 - 1 turn.
1 mission output shaft speed
sensor
Transmission output shaft 3) Connect T-adapter.
2
in normal state 2) Disconnect connectors ATC3A – CN5.
ness
CN5 (female) (1)
contact)
Resistance Max. 1 z
fective
HD465-7, HD605-7 20-587

(10)
TROUBLESHOOTING [DLT3LC]
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST

(LC)

Trouble Transmission output shaft speed sensor: *See separate list (LC)
E03 DLT3LC TM
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission intermediate shaft speed sensor signal is different from the signal speed of the
transmission output shaft speed sensor.
appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral.

1
2) Disconnect connectors ATC3A, BRC3A, and CN5.
2 ATC3A (female) (3),
ness Wiring harness between ATC3A
BRC3A (female) (13),
(female) (3) – BRC3A (female) (13) Min. 1 Mz
Possible causes CN5 (female) (1) –
2) Disconnect connectors ATC3A, BRC3A, – CN5.
3 Hot short in wiring harness Voltage between
(female) (3) – BRC3A (female) (13) BRC3A (female) (13), Max. 1 V
– CN5 (female) (female) (1) CN5 (female) (1) –
chassis ground
fective
20-588 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLT3KA]
HD465-7, HD605-7 20-589

(1)
TROUBLESHOOTING [DXH1KA]
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of lockup clutch solenoid: Discon-
Trouble
E03 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
tive Between CN20 (male) (1) – (2) Resistance 5 – 15 z
Between CN20 (male) (1), (2) – chassis
ground
Possible causes 2) Disconnect connectors ATC2 and CN20.
CN20 (female) (1)
contact)
Resistance Max. 1 z
CN20 (female) (2)
3
fective
ATC2 (female) (20)
20-590 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DXH1KB]
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of lockup clutch solenoid: Short cir-
Trouble
E03 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
tive
2) Disconnect connectors ATC2 and CN10.
Possible causes Resistance between
and standard value Short circuit in wiring har- Wiring harness between ATC2 (fe- ATC2 (female) (10),
in normal state 2 Min. 1 Mz
ness male) (10) – CN20 (female) (1) CN20 (female) (1) –
chassis ground
CN20 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz
(20) – CN20 (female) (2)
3
fective
ATC2 (female) (20)
HD465-7, HD605-7 20-591

(10)
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

1 Hi clutch ECMV defective
Between CN18 (male) (1), (2) – chassis
ground
Possible causes 2) Disconnect connectors ATC2 and CN18.
CN18 (female) (1)
contact)
Resistance Max. 1 z
CN18 (female) (2)
3
fective
ATC2 (female) (19)
20-592 HD465-7, HD605-7

(10)
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Failure 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.)

chassis ground
(19) – CN18 (female) (2)
3
fective
ATC2 (female) (19)
HD465-7, HD605-7 20-593

(10)
20-594 HD465-7, HD605-7

(7)
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

in normal state 2 Wiring harness between ATC2 (female) (7) –
CN16 (female) (1)
contact)
Resistance Max. 1 z
CN16 (female) (2)
3
fective
ATC2 (female) (17)
HD465-7, HD605-7 20-595

(10)
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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.)

chassis ground
(17) – CN16 (female) (2)
3
fective
ATC2 (female) (17)
20-596 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-597

(7)
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

CN6 (female) (1)
contact)
Resistance Max. 1 z
CN6 (female) (2)
3
fective
ATC2 (female) (13)
20-598 HD465-7, HD605-7

(10)
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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

chassis ground
(13) – CN6 (female) (2)
3
fective
ATC2 (female) (13)
HD465-7, HD605-7 20-599

(10)
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

2) Disconnect connectors ATC2 – CN8.
CN8 (female) (1)
contact)
Resistance Max. 1 z
CN8 (female) (2)
3
fective
ATC2 (female) (15)
20-600 HD465-7, HD605-7

(10)
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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

chassis ground
(15) – CN8 (female) (2)
3
fective
ATC2 (female) (15)
HD465-7, HD605-7 20-601

(10)
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

2) Disconnect connectors ATC2 – CN12.
CN12 (female) (1)
contact)
Resistance Max. 1 z
CN12 (female) (2)
3
fective
ATC2 (female) (18)
20-602 HD465-7, HD605-7

(10)
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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.)

chassis ground
(18) – CN12 (female) (2)
3
fective
ATC2 (female) (18)
HD465-7, HD605-7 20-603

(10)
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

CN10 (female) (1)
contact)
Resistance Max. 1 z
CN10 (female) (2)
3
fective
ATC2 (female) (15)
20-604 HD465-7, HD605-7

(10)
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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

chassis ground
(15) – CN10 (female) (2)
3
fective
ATC2 (female) (15)
HD465-7, HD605-7 20-605

(10)
TROUBLESHOOTING [DXHHKA]
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure 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.

CN14 (female) (1)
contact)
Resistance Max. 1 z
CN14 (female) (2)
3
fective
ATC2 (female) (13)
20-606 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DXHHKB]
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure 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

chassis ground
(13) – CN14 (female) (2)
3
fective
ATC2 (female) (13).
HD465-7, HD605-7 20-607

(10)
TROUBLESHOOTING TM-1
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY

(IT ALWAYS INDICATES "FULL")
Action code Failure code Controller code Fuel level gauge does not operate normally
Trouble
Not set Not set Not set (It always indicates "FULL")
• The fuel level gauge does not operate normally because of grounding fault (short circuit with GND) in
Contents of trouble
the signal circuit of the fuel level sensor.
Problem that
• The fuel level gauge always indicates "FULL".
appears on machine
Related information • If failure code "DJF1KA" is indicated, perform troubleshooting for it first.

1 Fuel level sensor defective 3) Connect T-adapter.
Between T01 Fuel level: When FULL Resistance Max. 12 z
Possible causes (female) (1) – (2) Fuel level: When EMPTY Resistance 74 – 100 z
and standard value
in normal state
2) Disconnect connectors ATC3B and T01.
ness
Min. 1 Mz
chassis ground
20-608 HD465-7, HD605-7

(10)
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER

a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Action code Failure code Controller code Abnormality in backup lamp and backup buzzer
Trouble a) When the shift lever is set in the "R" position, the backup lamp
Not set Not set Not set and backup buzzer are not turned ON
Contents of trouble • When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Problem that
• When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
appears on machine
• Before starting troubleshooting, check that fuse (BT-1) (16) is normal.
Related information
• Failure code is not displayed.

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (5) – (6).
Diode (D05)
No
Possible causes When diode (D05) is replaced, is failure re- is normal.
and standard value 2 Diode (D05) defective paired? Diode (D05)
in normal state Yes
is defective.
2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse (16) terminal.
Wiring harness between fuse BT1 terminal
Resistance Max. 1 z
(16) – R05 (female) (4)
Disconnection in wiring har- Wiring harness between R05 (female) (5) –
3 D05 (female) (1)
contact) Wiring harness between D05 (female) (2) –
ATC5B (female) (2), and branch point of CNS Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
CJT (female) (8)
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, if fail- is normal
4
tive ure repaired? Joint con-
Yes nector (CJT)
is defective
HD465-7, HD605-7 20-609

(10)
b) Backup lamp is not turned ON (Backup buzzer is normal)
Trouble
Not set Not set Not set b) Abnormality in backup lamp and backup buzzer
• When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
Contents of trouble
normal).
Problem that • When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
appears on machine normal).
Related information • Failure code is not displayed.

Backup lamp bulb is not broken. Backup lamp is normal
1 Backup lamp defective
Backup lamp bulb is broken. Backup lamp is defective
Disconnection in wiring har- 2) Disconnect connectors B04 and CJT.
Possible causes 2
and standard value Wiring harness between CJT (female) (2) –
in normal state
B04 terminal
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
c) Backup buzzer is not turned ON (Backup lamp is normal)
Trouble
Not set Not set Not set c) Backup buzzer is not turned ON (Backup lamp is normal)
• When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
Contents of trouble
normal).
Problem that • When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
appears on machine normal).
Cause Standard value in normal state/Remarks ON troubleshooting

2) Disconnect connectors B05, B06, and CJT.
Disconnection in wiring har- Wiring harness between CJT (female) (6) –
1 chassis ground
Wiring harness between B06 terminal – CJT
(female) (7) terminal
Possible causes
Wiring harness between B05 terminal – CJT
in normal state (female) (1) terminal
When results of Item a) and Cause 1 above are Backup buzzer is
2 Backup buzzer defective
normal defective
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
20-610 HD465-7, HD605-7

(10)
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON
Trouble d) While shift lever is not operated, backup lamp and backup
Not set Not set Not set buzzer are turned ON
Contents of trouble • While shift lever is not operated, backup lamp and backup buzzer are turned ON.
Problem that
• While shift lever is not operated, backup lamp and backup buzzer are turned ON.
appears on machine

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Possible causes tween (5) – (6).
in normal state 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse (16) terminal.
Voltage between R05
Wiring harness between R05 (fe- (female) (5), D05 (fe-
Max. 1 V
male) (5) – D05 (female) (1) male) (1) – chassis
ground
Wiring harness between D05 (fe-
Voltage between D05
male) (2) – ATC5B (female) (2), Max. 1 V
and branch point of CNS (female)
2 Hot short in wiring harness ground
(3)
Voltage between R05
Wiring harness between R05 (fe- (female) (3), CJT (fe- Max. 1 V
male) (3) – CJT (female) (8) male) (8) – chassis
ground
Voltage between CJT
Wiring harness between CJT (fe- Max. 1 V
(female) (1), B05 termi-
male) (1) – B05 terminal
nal – chassis ground
Voltage between CJT
Wiring harness between CJT (fe-
(female) (2), B04 termi- Max. 1 V
male) (2) – B04 terminal
HD465-7, HD605-7 20-611

(10)
20-612 HD465-7, HD605-7

(1)
TROUBLESHOOTING FOR RETARDER
CONTROLLER SYSTEM
(BK MODE)
Electrical system diagram related to retarder control .................................................................................. 20-704

Information in troubleshooting table ....................................................................................................... 20-706
Phenomenon 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)
(if equipped): 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 power source 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 (if equipped): 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 (if equipped):
out of input signal range (KX) .............................................................................................. 20-728
[DHP4KX] Failure in suspension pressure sensor (FR) system (if equipped):
[dHP5KX] Failure in suspension pressure sensor (FL) system (if equipped):
[DHP5KX] Failure in suspension pressure sensor (FL) system (if equipped):
[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 (if equipped): out of input signal range (KX)........... 20-740
[DK11KX] Failure in acceleration sensor system (if equipped): 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 (if equipped): *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 (if equipped) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754
[DW36KZ] Failure in output system of auto suspension solenoid 2 (if equipped) (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 proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760
HD465-7, HD605-7 20-701

(10)
[DX11KB] Short circuit in output circuit of proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761
[DX11KY] Grounding fault in output circuit of proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): short circuit with power source line (KY) .................................... 20-762
[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 source 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

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER

CONTROL
20-704 HD465-7, HD605-7

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
HD465-7, HD605-7 20-705

(5)

panel panel panel
Problem that
appears on machine

1
• Disconnection
• Ground fault
• Short circuit
indicate priority)
side.
side.
5
side.
20-706 HD465-7, HD605-7

(10)


★ Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Contents Phenomenon Contents
code code
KA Disconnection in wiring L0 Fill signals at two or more channels which are not set as combi-
nation are turned ON at the same time.
KK Source voltage reduction/ L2 Fuel pressure is above maxim specified value.

input
KQ Type select signal incon- L3 Object part is uncontrollable.

sistency
KY Short circuit with power LC rpm signals in two systems are inconsistent.
source (Hot short)
KZ Disconnection or short cir- LD Switch is pressed for usually unthinkable long time.
cuit
MW Sliding
NS Overheat
HD465-7, HD605-7 20-707

(10)
TROUBLESHOOTING [2G42ZG], [2G43ZG]
[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Front): Lowering of oil pressure (ZG)
E03 2G42ZG BK
• The signal of the front accumulator oil pressure sensor lowers below 13.2 MPa {135 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
• If the machine is used without repairing, the front brake may not work.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 35500)

• The front accumulator (brake) oil pressure is normal.
Possible causes Lowering of front accumula-
1 aIf the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
• If the front accumulator (brake) oil pressure is normal, the retarder
2 Retarder controller defective
controller is defective.
[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Rear): Lowering of oil pressure (ZG)
E03 2G43ZG BK
• The signal of the rear accumulator oil pressure sensor lowers below 8.83 MPa {90 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
• If the machine is used without repairing, the rear brake may not work.
appears on machine

• The rear accumulator (brake) oil pressure is normal.
Possible causes Lowering of rear accumula-
1 aIf the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
• If the rear accumulator (brake) oil pressure is normal, the retarder
controller is defective.
20-708 HD465-7, HD605-7

(10)
TROUBLESHOOTING [D1C0KZ]
[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code Failure code Controller code Brake cutout relay: Disconnection or short circuit (KZ)
Trouble
E03 D1C0KZ BK (Disconnection, grounding fault, or short circuit)
• When the output to the brake cutout relay circuit is turned ON, an abnormally large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
• The controller turns the output to the brake cutout relay OFF.
• When ARSC operates, the controller releases the brake gradually.
• The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC,
Problem that
ASR)
appears on machine
• Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

When the brake cutout relay (R14) No Relay (R14) is normal
is replaced, is failure repaired? Yes Relay (R14) is defective
3) Check the relay.
Brake cutout relay (R14) de-
1 Between R14 (male) (1) – (2) Resistance 200 – 400 z
fective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Between R14 (male) (1) – (2)
Resistance Min. 1 M z
tween (1) – (2)
2) Disconnect connectors BRC1 and R14.
Possible causes Wiring harness between fuse BR- Voltage between BRC1
20 – 30 V
and standard value 3-(12) – BRC1 (female) (4) (4) – chassis ground
in normal state
Disconnection in wiring har- Wiring harness between fuse BT- Voltage between R14 20 – 30 V
ness 3-(12) – R14 (female) (5) (5) – chassis ground
2
(Disconnection or defective 1) Turn the starting switch OFF.
contact) 2) Disconnect connectors BRC1, BRC2, and R14.
Wiring harness between BRC2 (female) (1),
Resistance Max. 1 z
(12) – R14 (female) (3)
Resistance Max. 1 z
chassis ground
Wiring harness between BRC1 (female) (13) –
Resistance Max. 1 z
R14 (female) (1)
3
ness Wiring harness between Resistance between BRC1
BRC1 (female) (13) – R14 (female) (13), R14 (female) Min. 1 M z
4 Hot short in wiring harness 4) Turn the starting switch ON.
Wiring harness between Voltage between BRC1 (fe-
BRC1 (female) (13) – R14 male) (13), R14 (female) (1) Max. 1 V
HD465-7, HD605-7 20-709

(10)
TROUBLESHOOTING [D1C0KZ]
20-710 HD465-7, HD605-7

(1)
TROUBLESHOOTING [D5ZNKZ]
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (IF EQUIPPED):
DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code Failure of front brake cutout output system (Disconnection, grounding
Trouble fault, short circuit) (if equipped): Disconnection or short circuit (KZ)
E03 D5ZNKZ BK (Disconnection, grounding fault, or short circuit)
• When the output to the front brake cutout switch circuit is turned ON, an abnormally large current flows
Contents of trouble
or any current does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to the brake cutout switch circuit OFF.
Problem that • When the front brake cutout switch is turned ON, the front brake cutout system does not work. Or, the
appears on machine front brake cutout system works while the switch is OFF.
Related information • This failure can be checked in the monitoring function (Code: 37600, 39100)

2) Disconnect connector FBC.
3) Check the switch.
Turn the front brake cutout
Front brake cutout switch Resistance Min. 1 M z
1 Between FBC switch OFF (Press it up).
defective
(male) (1) – (3) Turn the front brake cutout
Resistance Max. 1 z
switch ON (Press it down).
aWhen the front brake cutout switch is turned ON (pressed down), the
front brake is cut out (the front brake does not operate).
2) Disconnect connectors DPC2B and FBC.
Disconnection in wiring har- Wiring harness between DPC2B (female) (4) –
2 FBC (female) (3)
Wiring harness between fuse BTC-4 (8) – FBC
(female) (1)
Wiring harness between FBC (female) (1) –
Resistance Max. 1 z
chassis ground
and standard value
in normal state Resistance between
Ground fault in wiring har- Wiring harness between DPC2B DPC2B (female) (4),
3 Min. 1 M z
ness (female) (4) – FBC (female) (3) FBC (female) (3) –
chassis ground
Wiring harness between fuse Resistance between
BTC-4 (8) – FBC (female) (1) FBC (female) (1) – Min. 1 M z
★ In this case, the fuse is broken. chassis ground
Wiring harness between Voltage between DPC2B (fe-
DPC2B (female) (4) – FBC male) (4), FBC (female) (3) – Max. 1 V
2) Disconnect connector DPC2B
Turn the cutout switch OFF
Between Voltage 20 – 30 V
(Press it up).
DPC2B (4) –
chassis ground Turn the cutout switch ON
Voltage Max. 1 V
(Press it down).
HD465-7, HD605-7 20-711

(10)
TROUBLESHOOTING [D5ZNKZ]
20-712 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DB10KK]
[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)

Trouble Retarder controller: Lowering of source/input voltage (KK)
E03 DB10KK BK
• The voltages of both main power source voltage circuit and direct power source voltage circuit are be-
Contents of trouble
low 17 V.
Action of controller • None in particular. (The controller works as long as possible.)
Problem that
appears on machine
• If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), – (17) for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
1 Battery defective Battery voltage Voltage Min. 24 V
Specific gravity of battery fluid Specific gravity Min. 1.26
2) Disconnect connector BRC1.
Resistance Max. 1 z
ness Voltage between
2
(Disconnection or defective Wiring harness between battery, battery BRC1 (7) – (8), 20 – 30 V
contact) relay terminal B, – BRC1 (7)
(16)
Possible causes
and standard value
in normal state
Voltage between
Wiring harness between battery relay
BRC1 (9), (17) – 20 – 30 V
terminal M – BRC1 (9), (17)
(8), (16)
2) Disconnect connector BRC1
Between BRC1 (7) – (8), (16) Voltage 20 – 30 V
3 Retarder controller defective 1) Turn the starting switch OFF.
Between BRC1 (9), (17) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-713

(10)
20-714 HD465-7, HD605-7

(1)
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF

Action code Failure code Controller code Main power line of retarder controller: Lowering of source/input volt-
Trouble
E03 DB11KK BK age (KK)
Contents of trouble • The difference between the main power source voltage and direct power source voltage is 5 V or more.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (9) – (17) for grounding fault.

Resistance Max. 1 z
ness Voltage between bat-
1
(Disconnection or defective Wiring harness between battery – tery relay terminal B – 20 – 30 V
contact) battery relay terminal B
in normal state 2) Disconnect connector BRC1.
Voltage between
Wiring harness between battery
BRC1 (9), (17) – (8), 20 – 30 V
relay terminal M – BRC1 (9), (17)
(16)
Between BRC1 (9), (17) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-715

(10)
20-716 HD465-7, HD605-7

(1)
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/

INPUT VOLTAGE (KK)
Action code Failure code Controller code Retarder controller load power line: Lowering of source/input
Trouble
E03 DB12KK BK voltage (KK)
Contents of trouble • While the controller source voltage is normal, the solenoid source voltage is below 17 V.
• The controller turns the all output circuits OFF..
• The controller turns the 24 V sensor power source OFF.
Problem that
ASR)
appears on machine
• Failure codes (DHU2KX, DHU3KX) are displayed, too.
Related information • If the fuse is broken, check the line between the fuse – BRC1 (female) (4) – (17) for grounding fault.

When brake cutout relay (R14) is No Relay (R14) is normal.
replaced, is failure repaired? Yes Relay (R14) is defective.
3) Check the relay.
Brake cutout relay (R14) de-
1
fective Between R14 (male) (1) – (2) Resistance 200 – 400 z
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Between R14 (male) (1) – (2)
Possible causes (3) – (5) Do not apply voltage
and standard value between (1) – (2)
2) Disconnect connectors R14.
Disconnection in wiring har- Wiring harness between fuse BT-3 Voltage between R14
ness (female) (5) – chassis 20 – 30 V
2 (12) – R14 (female) (5)
(Disconnection or defective ground
contact) 1) Turn the starting switch OFF.
Wiring harness between BRC2 (1), (12) – R14
Resistance Max. 1 z
(female) (5)
Between BRC2 (1), (12) – chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-717

(10)
20-718 HD465-7, HD605-7

(1)
[DB13KK] DIRECT POWER SOURCE LINE OF RETARDER CONTROLLER BATTERY:

LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Direct power source line of retarder controller battery: Lowering of
Trouble
E03 DB13KK BK source/input voltage (KK)
Contents of trouble • The direct power source voltage is below 5 V.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse – BRC1 (female) (7) for grounding fault.

Resistance Max. 1 z
Disconnection in wiring har- (16) – chassis ground
1
(Disconnection or defective 2) Disconnect connector BRC1.
Possible causes contact) 3) Insert T-adapter.
in normal state Wiring harness between battery, Voltage between
battery relay terminal B, – BRC1 BRC1 (9), (17) – (8), 20 – 30 V
(7) (16)
Between BRC1 (7) – (8), (16) Voltage 20 – 30 V
HD465-7, HD605-7 20-719

(10)
TROUBLESHOOTING [DB19KM]
[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION

OR SETTING (KM)
Action code Failure code Controller code Retarder controller wiring harness: Mistake in operation or setting
Trouble (KM)
E03 DB19KM BK (Mistake in connection or defect in wiring harness)
• The connector check signal, that is input when the starting switch is turned to the ON position, does
Contents of trouble
not agree with setting in the controller.
• The controller turns the all output circuits OFF.
Problem that
ASR)
appears on machine
• Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

The connector of the connector check signal is connected normally.
1 aConnector check signal connector: BRC3A (1) (OPEN), BRC5A (1)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector BRC5A.
2
Wiring harness between BRC5A (female) (1) –
chassis ground
and standard value 2) Disconnect connector BRC3A.
3
Wiring harness between BRC3A
BRC3A (female) (1) – Min. 1 M z
chassis ground
4 Retarder controller
Resistance Max. 1 z
chassis ground
Between BRC3A (female) (1) – chassis ground Resistance Min. 1 M z
20-720 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DB1SKQ]
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF

Action code Failure code Controller code Wrong information on model selection: Disagreement of model selec-
Trouble
E03 DB1SKQ BK tion signals (KQ)
• Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or received model selection information is out of setting.
Problem that
appears on machine
Related information • Other failures are detected, too. (Failure codes [DAFSKQ], [DAQAKR], [DAQSKQ] are displayed.)

Possible causes Transmission controller de- aIf the failure is not repaired by replacing the retarder controller, the
1
and standard value fective transmission controller is defective.
in normal state aIf the failure is repaired by replacing the transmission controller, the
retarder controller is defective.
HD465-7, HD605-7 20-721

(10)
TROUBLESHOOTING [DDD7KX]
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (IF EQUIPPED): OUT
OF INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in travel speed set switch system (if equipped): Out of in-
Trouble put signal range (KX)
E03 DDD7KX BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of controller • When ARSC operates, the controller releases the brake gradually.
Problem that
appears on machine

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Register (250 z) defective 3) Connect T-adapter.
Between RE3 (female) (1) – (2) Resistance 250 ± 25 z
3 Resistor (1,020 z) defective 3) Connect T-adapter.
Between RE4 (female) (1) – (2) Resistance 1,020 ± 102 z
2) Disconnect connectors BRC3A, BRC3B, ARC, RE3, and RE4.
Disconnection in wiring har- RE3 (male) (1) Resistance Max. 1 z
ness
Possible causes 4 Wiring harness between BRC3B (female) (15)
and standard value – RE3 (male) (2) – ARC (female) (1)
contact)
in normal state Wiring harness between RE4 (male) (1) – ARC
Resistance Max. 1 z
(female) (3)
Wiring harness between RE4 (male) (2) – ARC
Resistance Max. 1 z
(female) (2)
2) Disconnect connectors BRC3A and BRC3B.
Between BRC3A (6) – (16) Voltage Approx. 5 V
5 Retarder controller defective 3) Insert T-adapter.
When set switch is ON Resistance 1,020 ± 102 z
When set switch is
Resistance 68 ± 6.8 z
Between BRC3B (fe- TOUCH UP
male) (15) – BRC3A When set switch is
(female) (16) Resistance 198 ± 19.8 z
TOUCH DOWN
When set switch is
CANCEL
20-722 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDD7KX]
HD465-7, HD605-7 20-723

(1)
TROUBLESHOOTING [DDD8KA]
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Action code Failure code Controller code ARSC system switch system: Disconnection (KA)
Trouble
E03 DDD8KA BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
1
Wiring harness between DPC2B (female) (1) –
ARSC (female) (3)
2) Replace the ARSC system switch with normal one.
ARSC system switch defec- 3) Turn the starting switch ON.
2
Possible causes tive When the ARSC system No System switch is normal
and standard value switch is replaced with nor-
in normal state mal one, is failure repaired? Yes System switch is defective
2) Disconnect connector DPC1.
3 Machine monitor defective 5) Turn the starting switch ON.
Turn the ARSC system
switch ON (Press it up).
DPC2B (1) –
chassis ground Turn the ARSC system
Voltage Max. 1 V
switch OFF (Press it down).
20-724 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDD8KB]
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Action code Failure code Controller code ARSC system switch system: Short circuit (KB)
Trouble
E03 DDD8KB BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

2) Disconnect connectors ARSC and DPC2B.
Wiring harness be- Voltage between
tween DPC2B (fe- DPC2B (female) (1),
Voltage Max. 1 V
male) (1) – ARSC ARSC (female) (3) –
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec- 3) Turn the starting switch ON.
2
and standard value tive When the ARSC system No System switch is normal
in normal state switch is replaced with nor-
mal one, is failure repaired? Yes System switch is defective
Turn the ARSC system
switch ON (Press it up).
DPC2B (1) –
chassis ground Turn the ARSC system Voltage Max. 1 V
switch OFF (Press it down).
HD465-7, HD605-7 20-725

(10)
TROUBLESHOOTING [dGR2L8]
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: *SEE

SEPARATE LIST (L8)
Action code Failure code Controller code Failure in retarder oil temperature sensor system: *See separate
Trouble list (L8)
E03 dGR2L8 BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, failure code "DGR2L8" is displayed.

Retarder brake oil tempera-
1 Brake oil temperature:
ture sensor defective Resistance 37 – 50 k z
Between T02 (male) 25°C
(1) – (2) Brake oil temperature:
Resistance 3.5 – 4.0 k z
100°C
Possible causes 2) Disconnect connectors BRC3B and T02.
and standard value Ground fault in wiring har- 3) Connect T-adapter.
in normal state 2
ness Wiring harness between Resistance between BRC3B
BRC3B (female) (3) – T02 (female) (3), T02 (female) Min. 1 M z
3 Retarder controller defective Brake oil temperature:
Between BRC3B (fe- Resistance 37 – 50 k z
25°C
male) (3) – BRC3A (fe-
Brake oil temperature:
male) (16) Resistance 3.5 – 4.0 k z
100°C
20-726 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DGR2L8]
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE SEPARATE LIST (L8)
Action code Failure code Controller code Brake oil temperature sensor (Rear): *See separate list (L8)
Trouble
E01 DGR2L8 BK (When ARSC is set and the ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
• When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed.

ture sensor defective Resistance 37 – 50 k z
Resistance 3.5 – 4.0 k z
100°C
Possible causes 2) Disconnect connectors BRC3B and T02.
and standard value Ground fault in wiring har- 3) Connect T-adapter.
in normal state 2
BRC3B (female) (3) – T02 (female) (3), T02 (female) Min. 1 M z
Between BRC3B (fe- Resistance 37 – 50 k z
25°C
Brake oil temperature:
male) (16) Resistance 3.5 – 4.0 k z
100°C
HD465-7, HD605-7 20-727

(10)
TROUBLESHOOTING [dHP4KX]
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM

(IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in suspension pressure sensor (FR) system (if equipped):
Trouble Out 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.
Problem that
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, failure code "DHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
Disconnection in wiring har- Wiring harness between BRC3A (female) (20)
1 – SUFR (female) (C)
Wiring harness between BRC3A (female) (16)
– SUFR (female) (A)
Wiring harness between PM6 (female) (2) –
Resistance Max. 1 z
SUFR (female) (B)
2) Disconnect connectors BRC3A SUFR and PM6.
Wiring harness between Resistance between BRC3A
2 BRC3A (female) (20) – (female) (20), SUFR (female) Min. 1 M z
ness
SUFR (female) (C) (C) – chassis ground
Wiring harness between Resistance between PM6
PM6 (female) (2)– SUFR (fe- (female) (2), SUFR (female) Min. 1 M z
Possible causes male) (B) (B) – chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
Wiring harness between Voltage between BRC3A (fe-
BRC3A (female) (20) – 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) – (A) Voltage 20 – 30 V
Between SUFR (C) – (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC3A.
Between BRC3A (20) – (16) Voltage 1.0 – 4.6 V
20-728 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-729

(5)
TROUBLESHOOTING [DHP4KX]
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FR) system (if equipped):
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, failure code "dHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
1 – SUFR (female) (C)
– SUFR (female) (A)
Resistance Max. 1 z
SUFR (female) (B)
2) Disconnect connectors BRC3A, SUFR and PM6.
2 BRC3A (female) (20) – (female) (20), SUFR (female) Min. 1 M z
ness
PM6 (female) (2) – SUFR (female) (2), SUFR (female) Min. 1 M z
Possible causes (female) (B) (B) – chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
BRC3A (female) (20) – male) (9), SUFR (female) Max. 1 V
4
Between SUFR (B) – (A) Voltage 18 ± 3 V
2) Disconnect connectors BRC3A.
BRC3A (20) – (16) Voltage 1.0 – 4.6 V
20-730 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-731

(5)
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FL) system (if equipped):
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.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, failure code "DHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 – SUFL (female) (C)
– SUFL (female) (A)
Resistance Max. 1 z
SUFL (female) (B)
2) Disconnect connectors BRC3A SUFL and PM6.
2 BRC3A (female) (19) – (female) (19), SUFL (female) Min. 1 M z
ness
SUFL (female) (C) (C) – chassis ground
PM6 (female) (2) – SUFL (female) (2), SUFL (female) Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and SUFL.
BRC3A (female) (20) – male) (9), SUFL (female) (C) Max. 1 V
SUFL (female) (C) – chassis ground
2) Disconnect connector SUFL.
4
Between SUFL (B) – (A) Voltage 18 ± 3 V
Between SUFL (C) – (A) Voltage 1.0 – 4.6 V
BRC3A (19) – (16) Voltage 1.0 – 4.6 V
20-732 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-733

(5)
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FL) system (if equipped):
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, failure code "dHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 – SUFL (female) (C)
– SUFL (female) (A)
Resistance Max. 1 z
SUFL (female) (B)
2) Disconnect connectors BRC3A, SUFL and PM6.
2 BRC3A (female) (19) – (female) (19), SUFL (female) Min. 1 M z
ness
PM6 (female) (2) – SUFL (female) (2), SUFL (female) Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and SUFL.
BRC3A (female) (20) – male) (9), SUFL (female) (B) Max. 1 V
SUFL (female) (C) – chassis ground
4
(FL) defective 5) Turn the starting switch ON.
Between SUFL (B) – (A) Voltage 18 ± 3 V
BRC3A (19) – (16) Voltage 1.0 – 4.6 V
20-734 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-735

(5)
TROUBLESHOOTING [DHU2KX]
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT

SIGNAL RANGE (KX)
Action code Failure code Controller code Accumulator oil pressure sensor (Front): Out of input signal
Trouble
E01 DHU2KX BK range (KX)
Contents of trouble • The signal circuit voltage of the front accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BRC1 and fuse BT3 terminal (12).
4) Connect the connector and fuse BT3 terminal (12).
Voltage between
Wiring harness between fuse BT3
BRC1 (5) – chassis 20 – 30 V
terminal(12) – BRC1 (female) (5)
Disconnection in wiring har- ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCF.
Resistance Max. 1 z
ACCF (female) (C)
Resistance Max. 1 z
– ACCF (female) (A)
Resistance Max. 1 z
ACCF (female) (B)
2) Disconnect connectors BRC3B and ACCF.
2 BRC3A (female) (9) – ACCF (female) (9), ACCF (female) Min. 1 M z
(female) (C) (C) – chassis ground
and standard value
in normal state Wiring harness between Resistance between BRC1
BRC1 (female) (14) – ACCF (female) (3), ACCF (female) Min. 1 M z
(female) (B) (B) – chassis ground
2) Disconnect connectors BRC3A and ACCF.
BRC3A (female) (9) – ACCF male) (9), ACCF (female) Max. 1 V
2) Disconnect connector ACCF.
Front accumulator oil pres- 4) Connect the connector.
4
Between ACCF (B) – (A) Voltage 20 – 30 V
Between ACCF (C) – (A) Voltage 0.5 – 4.5 V
2) Disconnect connectors BRC1 and BRC3A.
Between BRC1 (14) – BRC3A (16) Voltage 20 – 30 V
BRC3A (9) – (16) Voltage 0.5 – 4.5 V
20-736 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-737

(1)
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure code Controller code Accumulator oil pressure sensor (Rear): Out of input signal
Trouble
E01 DHU3KX BK range (KX)
Contents of trouble • The signal circuit voltage of the rear accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BTC1 and fuse BT3 terminal (12).
4) Connect the connector and fuse BT3 terminal (12).
Voltage between
Wiring harness between fuse BT3
BRC1 (5) – chassis 20 – 30 V
Disconnection in wiring har- terminal (12) – BRC1 (female) (5) ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCR.
Resistance Max. 1 z
– ACCR (female) (C)
Resistance Max. 1 z
– ACCR (female) (A)
Resistance Max. 1 z
ACCR (female) (B)
2) Disconnect connectors BRC3B and ACCR.
2 BRC3A (female) (10) – (female) (10), ACCR (fe- Min. 1 M z
ACCR (female) (C) male) (C) – chassis ground
and standard value
BRC1 (female) (14) – ACCR (female) (3), ACCR (female) Min. 1 M z
2) Disconnect connectors BRC3A and ACCR.
BRC3A (female) (10) – male) (10), ACCR (female) Max. 1 V
ACCR (female) (C) (C) – chassis ground
2) Disconnect connector ACCR.
Rear accumulator oil pres- 4) Connect the connector.
4
Between ACCR (B) – (A) Voltage 20 – 30 V
Between ACCR (C) – (A) Voltage 0.5 – 4.5 V
2) Disconnect connectors BRC1 and BRC3A.
Between BRC1 (14) – BRC3A (16) Voltage 20 – 30 V
BRC3A (10) – (16) Voltage 0.5 – 4.5 V
20-738 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-739

(1)
TROUBLESHOOTING [dK11KX]
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF

INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in acceleration sensor system (if equipped): Out of input
Trouble signal range (KX)
E03 dK11KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Problem that
appears on machine
• If the failure code "DK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
• When ARSC is not set or the ARSC system switch is OFF, failure code "DK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
Wiring harness between BRC3B (female) (11)
– ATC3B (female) (11)
2) Disconnect connectors BRC3B and ATC3B.
and standard value 2 Resistance between
ness Wiring harness between BRC3B
BRC3B (female) (11),
in normal state (female) (11) – ATC3B (female) Min. 1 M z
ATC3B (female) (11) –
(11)
chassis ground
Between BRC3B (female) (11) – chassis
Voltage 0.6 – 4.75 V
ground
20-740 HD465-7, HD605-7

(10)
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF

INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in acceleration sensor system (if equipped): Out of input
Trouble signal range (KX)
E03 DK11KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Action of controller • ARSC does not operate.
Problem that
appears on machine
• If the failure code "dK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
• When ARSC is set and the ARSC system switch is ON, failure code "dK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
– ATC3B (female) (11)
2) Disconnect connectors BRC3B and ATC3B.
and standard value 2 Resistance between
ness Wiring harness between BRC3B
BRC3B (female) (11),
in normal state (female) (11) – ATC3B (female) Min. 1 M z
ATC3B (female) (11) –
(11)
chassis ground
Between BRC3B (female) (11) – chassis
ground
HD465-7, HD605-7 20-741

(10)
TROUBLESHOOTING [DK51L5]
[DK51L5] RETARDER LEVER POTENTIOMETER: *SEE SEPARATE LIST (L5)

Trouble Retarder lever potentiometer: *See separate list (L5)
E03 DK51L5 BK
• The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
Contents of trouble
the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
• Controls with the potentiometer signal.
• Limits the output for the solenoid to 70%.
• Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that • This failure does not have a serious effect on the machine.
appears on machine • The retarder cannot control finely.
• The retarder does not operate (The foot brake operates, however).

2) Disconnect connectors BRC2, BRC3A, BRC3B, BRC5A, RE1, and RTL.
Resistance Max. 1 z
RE1 (female) (1)
Wiring harness between RE1 (female) (2) –
Resistance Max. 1 z
RTL (female) (1)
1 – RTL (female) (3)
– RTL (female) (2)
Resistance Max. 1 z
RTL (female) (4)
Resistance Max. 1 z
RTL (female) (5)
Wiring harness between RTL (female) (6) –
Resistance Max. 1 z
chassis ground
2) Disconnect connectors BRC3B, and RE1, and RTL.
and standard value
BRC2 (female) (16) – RE1 (female) (16), RE1 (female) Min. 1 M z
2
ness Wiring harness between Resistance between RE1
RE1 (female) (2) – RTL (fe- (female) (2), RTL (female) Min. 1 M z
male) (1) (1) – chassis ground
Wiring harness between Resistance between BRC3B
BRC3B (female) (16) – RTL (female) (16), RTL (female) Min. 1 M z
2) Disconnect connectors BRC3B and RTL.
Wiring harness between Voltage between BRC2 (fe-
BRC2 (female) (16) – RE1 male) (16), RE1 (female) (1) Max. 1 V
3 Hot short in wiring harness (female) (1) – chassis ground
Wiring harness between Voltage between RE1 (fe-
RE1 (female) (2) – RTL (female) (2), RTL (female) (1) – Max. 1 V
male) (1) chassis ground
Wiring harness between Voltage between BRC3B (fe-
BRC3B (female) (16) – RTL male) (16), RTL (female) (2) Max. 1 V
20-742 HD465-7, HD605-7

(10)

4 Resistor (RE1) defective 3) Connect T-adapter.
Between RE1 (male) (1) – (2) Resistance 250 z
2) Disconnect connector RTL
4) Insert the connector.
6) Check the potentiometer.
Between RTL (1) – (3) Voltage 4.1 – 4.8 V
Between RTL (2) – (3) Voltage 0.3 – 4.7 V
5 Retarder lever defective 2) Disconnect connector RTL
Between RTL (male) Lever at OFF position Resistance Max. 1 z

(4) – (6) Lever at ON position Resistance Min. 1 M z
Possible causes
and standard value
in normal state Between RTL (male) Lever at OFF position Resistance Min. 1 M z
(5) – (6) Lever at ON position Resistance Max. 1 z
2) Disconnect connectors BRC2, BRC3A, and BRC3B.
Between BRC2 (16) – BRC3A (16) Voltage 4.1 – 4.8 V
Between BRC3B (16) – BRC3A (16) Voltage 0.3 – 4.7 V
6 Retarder controller defective 2) Disconnect connector RTL.
Between BRC5A (fe- Lever at OFF position Resistance Max. 1 z
ground Lever at ON position Resistance Min. 1 M z
Between BRC5A (fe- Lever at OFF position Resistance Min. 1 M z
ground Lever at ON position Resistance Max. 1 z
HD465-7, HD605-7 20-743

(10)
20-744 HD465-7, HD605-7

(1)
[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX)

Action code Failure code Controller code Dump lever potentiometer 1: Out of input signal range (KX)
Trouble
E03 DK52KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble • The signal voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V.
Action of controller • The controller recognizes the dump lever position as "HOLD".
Problem that
• The dump body does not operate.
appears on machine

2) Disconnect connectors BRC3A, BRC3B, and HSL.
Disconnection in wiring har- HSL (female) (4) Resistance Max. 1 z
ness
1 Wiring harness between BRC3B (female) (14)
– HSL (female) (2)
contact)
Resistance Max. 1 z
Resistance Max. 1 z
BRC3A (female) (6) – HSL (female) (6), HSL (female) Min. 1 M z
2
BRC3B (female) (14) – HSL (female) (14), HSL (female) Min. 1 M z
Possible causes Wiring harness between Resistance between BRC3B
and standard value BRC3B (female) (12) – HSL (female) (12), HSL (female) Min. 1 M z
in normal state (female) (3) (3) – chassis ground
BRC3A (female) (6) – HSL male) (6), HSL (female) (4) – Max. 1 V
3 Hot short in wiring harness (female) (4) chassis ground
BRC3B (female) (14) – HSL male) (14), HSL (female) (2) Max. 1 V
BRC3B (female) (12) – HSL male) (12), HSL (female) (3) Max. 1 V
2) Disconnect connector HSL.
4 Dump lever defective 5) Turn the starting switch ON.
Between HSL (4) – (1) Voltage 4.6 – 5.4 V
HD465-7, HD605-7 20-745

(10)

in normal state 5 Retarder controller defective 5) Turn the starting switch ON.
20-746 HD465-7, HD605-7

(10)
[DK53L8] DUMP LEVER POTENTIOMETER 2: *SEE SEPARATE LIST (L8)
Action code Failure code Controller code Dump lever potentiometer 2: *See separate list (L8)
Trouble (Out of total range of input signal voltage of lever potentiometer
E03 DK53L8 BK 1 or 2)
Contents of trouble • The total voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
Action of controller • The controller recognizes the dump lever position as "NEUTRAL".
Problem that
appears on machine
• This failure can be checked in the monitoring function (Code: 34300, 34301).
Related information
• If the failure code "DK52KX" is displayed, perform troubleshooting for it.

2) Disconnect connector HSL.
Possible causes
1 Dump lever defective 5) Turn the starting switch ON.
and standard value
in normal state Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Between HSL (3) –(1) Voltage 0.3 – 4.7 V
• If the failure is not repaired by performing the troubleshooting in 1
above, the retarder controller is defective.
HD465-7, HD605-7 20-747

(10)
[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code Failure code Controller code Body positioner sensor: Out of input signal range (KX)
Trouble
E03 DK54KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble • The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
• The controller controls dumping according to the dump level signal.
• The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that • The dump lever positioner does not function.
appears on machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the dump lever is not at FLOAT.
Related information • This failure can be checked in the monitoring function (Code: 34300, 34301, 34400, 34600).

2) Disconnect connectors BRC3A, BRC3B, and B07.
Disconnection in wiring har- Wiring harness between BRC3A (female)(6) –
1 B07 (female) (C)
– B07 (female) (B)
Resistance Max. 1 z
– B07 (female) (A)
2 BRC3A (female) (6) – B07 (female) (6), B07 (female) Min. 1 M z
ness
BRC3B (female) (13) – B07 (female) (13), B07 (female) Min. 1 M z
Possible causes 2) Disconnect connectors BRC3A, BRC3B, and B07.
and standard value 3) Connect T-adapter.
BRC3A (female) (6) – B07 male) (6), B07 (female) (C) – Max. 1 V
(female) (C) chassis ground
BRC3B (female) (13) – B07 male) (13), B07 (female) (B) Max. 1 V
(female) (B) – chassis ground
2) Disconnect connector B07.
4 Body positioner defective 4) Connect the connector.
Between B07 (C) – (A) Voltage 4.6 – 5.4 V
Between B07 (B) – (A) Voltage 0.3 – 4.7 V
20-748 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-749

(1)
TROUBLESHOOTING [DKD0L6]
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (IF EQUIPPED): *SEE SEPARATE

LIST (L6)
Action code Failure code Controller code Failure in steering speed sensor (if equipped): *See separate list
Trouble
E01 DKD0L6 BK (L6)
• Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sensor
Contents of trouble
and no signals are input.
Problem that
appears on machine

2) Disconnect connectors BRC2, BRC3A, and SR2.
1 – SR2 (female) (2)
– SR2 (female) (3)
Resistance Max. 1 z
SR2 (female) (1)
2) Disconnect connectors BRC2, BRC3A, and SR2.
2 BRC3A (female) (14) – SR2 (female) (14), SR2 (female) Min. 1 M z
ness
BRC2 (female) (14) – SR2 (female) (14), SR2 (female) Min. 1 M z
2) Disconnect connector SR2.
6) Turn the steering wheel slowly.
Steering speed sensor de- Between SR2 (1) – (3) Voltage 10 – 13 V
3
fective
Between SR2 (2) – (3) Voltage See FIG-1.
Between BRC2 (14) – (21) Voltage 10 – 13 V
4 Retarder controller defective 1) Turn the starting switch OFF.
6) Turn the steering wheel slowly.
Between BRC3A (12) – (14) Voltage See FIG-1.
20-750 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DKD0L6]
HD465-7, HD605-7 20-751

(1)
TROUBLESHOOTING [dLt3KA]
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Failure code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E01 dLt3KA BK (When ARSC is set and ARSC system switch is ON)
• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, failure code "dLT3KA" is displayed.

aFor details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
Possible causes Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and CN5.
ness
3 Wiring harness between BRC3A (female) (13)
contact)
Resistance Max. 1 z
2) Disconnect connectors BRC3A and ATC3A.
4 Retarder controller defective 3) Connect T-adapter.
Between BRC3A (female) (13) – (14) Resistance 500 – 1,000 z
20-752 HD465-7, HD605-7

(10)
TROUBLESHOOTING [dLT3KA]
[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Failure code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E03 dLT3KA BK (When ARSC is not set or ARSC system switch is OFF)
• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, failure code "dLT3KA" is displayed.

aFor details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
Possible causes Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and CN5.
ness
3 Wiring harness between BRC3A (female) (13)
contact)
Resistance Max. 1 z
2) Disconnect connectors BRC3A and ATC3A.
HD465-7, HD605-7 20-753

(10)
TROUBLESHOOTING [DW35KZ]
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (IF

EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in output system of auto suspension solenoid 1 (if
Trouble equipped) (Disconnection, grounding fault, short circuit): Discon-
E01 DW35KZ BK nection or 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) – (2) Resistance 15 – 35 z
Between S04 (female) (1), (2) – chassis
ground
Possible causes
2) Disconnect connectors BRC1 and S04.
2 Wiring harness between BRC1 (female) (1) –
S04 (female) (1)
contact)
Wiring harness between S04 (female) (2) –
Resistance Max. 1 z
chassis ground
Between BRC1 (female) (1) – chassis ground Resistance 15 – 20 z
20-754 HD465-7, HD605-7

(10)
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (IF

EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in output system of auto suspension solenoid 2 (if
Trouble equipped) (Disconnection, grounding fault, short circuit): Discon-
E01 DW36KZ BK nection or 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) – (2) Resistance 15 – 35 z
Between S05 (female) (1), (2) – chassis
ground
Possible causes
2) Disconnect connectors BRC1 and S05.
S05 (female) (1)
contact)
Wiring harness between S05 (female) (2) –
Resistance Max. 1 z
chassis ground
HD465-7, HD605-7 20-755

(10)
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in kick-out solenoid output system (D_OUT3) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E01 DW72KZ BK cuit (KZ)
• When the output to the dump lever kick-out solenoid circuit is ON, a too large current flows or any cur-
Contents of trouble
rent does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to the dump lever kick-out solenoid OFF.
Problem that
• Detent lock is not applied to the dump lever.
appears on machine

2) Disconnect connectors BRC1 and LK0.
ness
1 Wiring harness between LK0 (female) (2) –
chassis ground
contact)
Resistance Max. 1 z
LK0 (female) (1)
2) Disconnect connectors BRC1 and LK0.
and standard value Voltage between
in normal state Wiring harness between BRC1 BRC1 (female) (11),
Max. 1 V
(female) (11) – LK0 (female) (1) LK0 (female) (1) –
chassis ground
2) Disconnect connector LK0.
Dump lever kick-out sole- 3) Connect T-adapter.
3
noid defective
Between LK0 (male) (1) – (2) Resistance 39 z ± 5%
Between LK0 (male) (1), (2) – chassis ground Resistance Min. 1 M z
2) Disconnect connector LK0.
Between BRC1 (female) (11) – chassis ground Resistance 39 z ± 5%
20-756 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-757

(1)
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in hoist select valve output system (D_OUT5) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E03 DW73KZ BK cuit (KZ)
• When the output to the dump lever select valve solenoid circuit is ON, a too large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
• The controller turns the output to the dump lever select valve solenoid OFF.
• The controller turns the output to the dump lever EPC valve solenoid OFF.
Problem that
appears on machine

2) Disconnect connectors BRC1 and HSOL.
ness
1 Wiring harness between HSOL (female) (B) –
chassis ground
contact)
Resistance Max. 1 z
HSOL (female) (A)
2) Disconnect connectors BRC1 and HSOL.
Possible causes 2 Hot short in wiring harness
Voltage between
and standard value
Wiring harness between BRC1 BRC1 (female) (12),
in normal state Max. 1 V
(female) (12) – HSOL (female) (A) HSOL (female) (A) –
chassis ground
2) Disconnect connector HSOL.
Dump lever select valve so- 3) Connect T-adapter.
3
lenoid defective Between HSOL (male) (A) – (B) Resistance 15 – 35 z
Between HSOL (male) (A), (B) – chassis
ground
2) Disconnect connector HSOL.
20-758 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-759

(1)
TROUBLESHOOTING [DK11K4]
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: UNCONTROLLABLE (K4)
Action code Failure 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 z
male) (1) – (2) Oil pressure OFF Resistance Min. 1 M z
2) Disconnect connector BRC5A and RESW.
Ground fault in wiring har- 4) Connect connector.
3 5) Turn starting switch ON.
ness
Possible causes
and standard value Wiring harness between Resistance between BRC5A
in normal state BRC5A (female) (4) – (female) (4), RESW (female) Max. 1 z
RESW (female) (1) (1) – chassis ground
4 Hot short in wiring harness 5) Turn starting switch ON.
BRC5A (female) (4) – male) (4), RESW (female) Max. 1 V
5 Defective retarder controller 4) Connect connector.
5) Turn starting switch ON.
Between BRC5A (4) – Oil pressure ON Voltage Max. 1 V
shassis ground Oil pressure OFF Voltage 20 – 30 V
20-759-1 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DK11K4]
HD465-7, HD605-7 20-759-2

(5)
TROUBLESHOOTING [DX11KA]
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):
DISCONNECTION (KA)
Action code Failure 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) – (2) Resistance 10 – 30 z
Between RETV (female) (1), (2) – chassis
ground
Possible causes
2) Disconnect connectors BRC2 and RETV.
RETV (female) (1).
contact)
Resistance Max. 1 z
RETV (female) (2).
2) Disconnect connector BRC.
Between BRC2 (female) (7) – (17) Resistance 10 – 30 z
20-760 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX11KB]
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT
CIRCUIT (KB)
Action code Failure 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.
and standard value Resistance between
in normal state Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (9),
2 Min. 1 M z
cuit in wiring harness (female) (7) – RETV (female) (1). RETV (female) (1) –
chassis ground.
Wiring harness between BRC2 (female) (7) – RETV (fe-
male) (1) and between BRC (female) (17) – RETV (female) Min. 1 M z
(2)
HD465-7, HD605-7 20-761

(10)
TROUBLESHOOTING [DX11KY]
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT
CIRCUIT WITH POWER SOURCE LINE (KY)
Action code Failure 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 source 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.
2 Hot short in wiring harness Voltage between
Max. 1 V
(female) (7) – RETV (female) (1). RETV (female) (1) –
chassis ground.
20-762 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX11MA]
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: MALFUNCTION (MA)
Action code Failure 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 z
male) (1) – (2) Oil pressure OFF Resistance Min. 1 M z
Possible causes
and standard value 1) Turn starting switch OFF.
in normal state 2) Disconnect connector BRC5A – RESW.
3
ness Wiring harness between Resistance between BRC5A
BRC5A (female) (4) – (female) (4), RESW (female) Max. 1 z
Between BRC5A (4) – Oil pressure ON Voltage Max. 1 V
chassis ground (16) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-762-1

(10)
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

DISCONNECTION (KA)
Action code Failure 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
appears on machine

2) Disconnect connector HEPC.
Dump EPC valve solenoid
1
defective Between HEPC (female) (1) – (2) Resistance 15 – 20 z
Between HEPC (female) (1), (2) – chassis
ground
Possible causes
2) Disconnect connectors BRC2 and HEPC.
and standard value
in normal state
ness
HEPC (female) (1).
contact)
Resistance Max. 1 z
HEPC (female) (1).
19. Between BRC2 (female) (10) – (20) Resistance 15 – 20 z
HD465-7, HD605-7 20-763

(10)
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT (KB)
Action code Failure 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) – (2) Resistance 15 – 20 z
defective
ground
and standard value
Resistance between
in normal state
Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (10),
Min. 1 M z
2 (female) (10) – HEPC (female) (1). HEPC (female) (1) –
cuit in wiring harness
chassis ground.
Wiring harness between BRC2 (female) (10) – HEPC (fe-
male) (1) and between BRC2 (female) (20) – HEPC (fe- Min. 1 M z
male) (2)
20-764 HD465-7, HD605-7

(10)
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT WITH POWER SOURCE LINE (KY)
Action code Failure code Controller code Short circuit in output circuit of hoist EPC valve (A_OUT3): Short
Trouble
E03 DX13KY BK circuit with power source 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) – (2) Resistance 15 – 20 z
ground
and standard value Voltage between
in normal state Hot short in wiring harness
2 (Contact with power source Max. 1 V
(female) (10) – HEPC (female) (1). HEPC (female) (1) –
wiring harness)
chassis ground.
Voltage between
Max. 1 V
(female) (20) – HEPC (female) (2). HEPC (female) (2) –
chassis ground.
HD465-7, HD605-7 20-765

(10)
20-766 HD465-7, HD605-7

(1)
TROUBLESHOOTING BK-1
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY

a) When the parking brake switch is set in the OFF position, the parking brake is not released
Action code Failure code Controller code Parking brake does not operate normally
Trouble a) When the parking brake switch is set in the OFF position, the
Not set Not set BK parking brake is not released
Contents of trouble • When the parking brake switch is set in the OFF position, the parking brake is not released.
Problem that
• When the parking brake switch is set in the OFF position, the parking brake is not released.
appears on machine
• Before performing the troubleshooting, check that fuse (BT4) (4) is not broken. (If the fuse is broken,
Related information check its wiring harness for grounding fault.)

Parking brake switch
When parking brake switch (R33) No
(R33) is normal
is disconnected, does parking
brake operate? Parking brake switch
Yes
(R33) is defective
Parking brake switch defec- 3) Connect T-adapter.
1
tive Set the parking brake switch
Between R33 in PARK.
(male) (1) – (2) Set the parking brake switch
Resistance Max. 1 z
in OFF.
Set the parking brake switch
Resistance Max. 1 z
in OFF.
2) Disconnect connector PSOL
Parking brake solenoid de- 3) Connect T-adapter.
2
fective Between PSOL (male) (1) – (2) Resistance 30 – 50 z
Between PSOL (male) (1), (2) – chassis
Possible causes Resistance Min. 1 M z
and standard value ground
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective
3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
HD465-7, HD605-7 20-767

(10)

2) Disconnect connectors R19, R33, PSOL, fuse BT4 (4).
Wiring harness between fuse BT4 (4) – R19
Possible causes Disconnection in wiring har- (female) (5), R33 (female) (3) Resistance Max. 1 z
4 Wiring harness between R19 (female) (1), (3)
in normal state (Disconnection or defective Resistance Max. 1 z
– R33 (female) (1)
contact)
Resistance Max. 1 z
PSOL (female) (1)
Wiring harness between PSOL (female) (2) –
Resistance Max. 1 z
chassis ground
20-768 HD465-7, HD605-7

(10)
b) When the parking brake switch is set in the PARK position, the parking brake does not work
Action code Failure code Controller code Parking brake does not operate normally
Trouble b) When the parking brake switch is set in the PARK position, the
Not set Not set Not set parking brake does not work
Contents of trouble • When the parking brake switch is set in the PARK position, the parking brake does not work.
Problem that
• When the parking brake switch is set in the PARK position, the parking brake does not work.
appears on machine

Parking brake switch defec- (male) (1) – (2)
1 Set the parking brake switch
tive Resistance Max. 1 z
in OFF.
Resistance Max. 1 z
in OFF.
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective

and standard value 2) Disconnect connector R19.
in normal state 3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
2) Disconnect connectors R33 and PSOL.
3 Hot short in wiring harness Voltage between R33
Wiring harness between R33 (fe- (female) (2), PSOL (fe-
Max. 1 z
male) (2) – PSOL (female) (1) male) (1) – chassis
ground
HD465-7, HD605-7 20-769

(10)
20-770 HD465-7, HD605-7

(1)
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE

NORMALLY
Action code Failure code Controller code Retarder brake oil temperature gauge does not operate normally
Trouble
Not set Not set Not set (When ARSC is not set or ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature gauge is below 0.75 V.
Problem that • This failure does not have a serious effect on the machine.
appears on machine • When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed.

ture gauge defective Resistance 37 – 50 kz
Resistance 3.5 – 4.0 kz
100°C
2) Disconnect connectors BRC3B and T02.
and standard value 4) Turn the starting switch ON.
in normal state 2 Hot short in wiring harness
Voltage between
Wiring harness between BRC3B BRC3B (female) (3),
Max. 1 V
chassis ground
Between BRC3B (fe- Resistance 37 – 50 kz
25°C
male) (16) Brake oil temperature:
Resistance 3.5 – 4.0 kz
100°C
HD465-7, HD605-7 20-771

(10)
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED

(WHEN MACHINE IS NOT INCLINED MORE THAN 15°)
Action code Failure code Controller code Inclination alarm is turned ON when dump body is raised
Trouble
Not set Not set Not set (When machine is not inclined more than 15°)
• The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
Contents of trouble
more than 15°)
Problem that • The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
appears on machine more than 15°)
• If the inclination alarm is turned ON while the machine is incline more than 15°, it is not defective (it is
Related information normal).

1 Inclination sensor defective
Inclination is below 15° Resistance Max. 1 z
Between SR3 (male)
Inclination is 15° or
(1) – (2) Resistance Min. 1 M z
more
Possible causes Disconnection in wiring har- 2) Disconnect connectors BRC5A and SR3.
– SR3 (female) (1)
Between BRC5A (fe- Inclination is below 15° Resistance Max. 1 z
male) (12) – chassis Inclination is 15° or
ground Resistance Min. 1 M z
more
20-772 HD465-7, HD605-7

(10)
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED
Action code Failure code Controller code Touch up/down and cancellation cannot be performed.
Trouble
Not set Not set Not set (When ARSC is set and ARSC system switch is ON)
Contents of trouble • Touch up/down and cancellation cannot be performed.
Problem that
• Touch up/down and cancellation cannot be performed.
appears on machine
Related information • If failure code "DDD7KX" is displayed, perform troubleshooting for it.

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective

2 Register (250 z) defective 3) Connect T-adapter.
Between RE3 (female) (1) – (2) Resistance 250 ± 25 z
3 Resistor (1,020 z) defective 3) Connect T-adapter.
Between RE4 (female) (1) – (2) Resistance 1,020 ± 102 z

Disconnection in wiring har- 2) Disconnect connectors BRC3A, ARC, and RE4.
Possible causes ness 3) Connect T-adapter.
4
and standard value (Disconnection or defective
in normal state contact) Resistance Max. 1 z
– ARC (female) (3)
4) Connect the connectors.
Between BRC3A (6) – (16) Voltage Approx. 5 V
5 Retarder controller defective 2) Disconnect connectors BRC3A and BRC3B.
When set switch is ON Resistance 1,020 ± 102 z
Between BRC3B When set switch is TOUCH
(female) (15) – UP
BRC3A (female) When set switch is TOUCH
(16) Resistance 198 ± 19.8 z
DOWN
When set switch is CANCEL Resistance 418 ± 41.8 z
HD465-7, HD605-7 20-773

(10)
20-774 HD465-7, HD605-7

(1)
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
Phenomenon 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 (Hot short)
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 (Hot short)
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

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802 HD465-7, HD605-7

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
HD465-7, HD605-7 20-803

(2)
SERVICE CODES OF PAYLOAD METER (CARD TYPE)
TROUBLESHOOTING AND CONTENTS OF SELF-DIAGNOSIS
SERVICE CODES OF PAYLOAD METER (CARD TYPE) AND CONTENTS OF SELF-

DIAGNOSIS
The following are displayed on the display unit of Payload Meter (Card type). (They are not displayed on the
monitor panel.)
Priority of
display Contents Service code External pilot lamps
b-FL lighting up All lighting up

Dump lever is not in FLOAT position (Truck is not
1
dumping)
b-FL lighting up —
2 Memory card is not inserted Cd flashing —
3 Backup battery voltage is lowered F-09 flashing —
Cycle data memory is FULL
Engine ON/OFF data is FULL

See (*1) on next
4 —
page.
Abnormality warning data memory is FULL
Data memory of integrated pay load and total number
of cycle is FULL
5 Disconnection of terminal R F-18 flashin All flashing
6 Abnormality in sensor power source (18 V) F-20 flashin All flashing

Short circuit with chassis ground or disconnection in
7 F-21 flashin All flashing
front left suspension pressure sensor system
8 front right suspension pressure sensor system F-22 flashin All flashing
9 Short circuit with chassis ground or disconnection in F-23 flashin All flashing
rear left suspension pressure sensor system
10 rear right suspension pressure sensor system F-24 flashin All flashing
Short circuit with power source in front left suspension
11 pressure sensor system F-25 flashin All flashing
Short circuit with power source in front right suspension
13 Short circuit with power source in rear left suspension F-27 flashin All flashing
Short circuit with power source in rear right suspension
14 pressure sensor system F-28 flashin All flashing
Short circuit with chassis ground or disconnection in cli-
nometer system
16 Short circuit with power source of clinometer system F-32 flashin All flashing
17 Calibration has not been performed or RAM is abnor- F • CAL flashin All flashing
mal
Related lamps
18 Short circuit in external pilot lamp G relay F-43 flashin While stopped: Kept lighted up
While traveling: Turned OFF
19 Short circuit in external pilot lamp Y relay F-44 flashin Other lamps
While loading: Normal operation
While stopped without loading:
20 Short circuit in external pilot lamp R relay F-45 flashin Flashing
While traveling: Turned OFF
21 Pay load in cycle data is inaccurate [See (*2) in page L. bad flashin —
20-806]
22 Higher than limit speed SP : SP flashin —
F-71 flashin
F-73 flashin
F-80 flashin
F-81 flashin
F-91 flashin
23 Communication defective or wrong option code setting F-92 flashin —
F-93 flashin
F-94 flashin
F-95 flashin
F-96 flashin
F-97 flashin
F-98 flashin
20-804 HD465-7, HD605-7

(1)
(*1) Alarm displayed when memory is FULL abnormality/warning data are deleted
1. Cycle data from the oldest one. (The alarm of "2)"
1) If the number of saved cycles reaches above is maintained.)
2600 (the remaining capacity is 300
cycles or less), the following is repeated. 4. Integrated pay load/Total number of
L : FUL flashes 7 times. cycles data
: flashes 1 time. 1) If the total number of cycles reaches
2) If the number of saved cycles reaches 9994 (the remaining capacity is 5 cycles
2900 (the remaining capacity is 0 cycle), or less) or the difference between the
the following is repeated. saved integrated pay load and 999900
L : FUL lights up (for 3 seconds). tons (upper limit) becomes 5 times the
: flashes 1 time. rated hauling capacity, the following is
3) If the number of saved cycles exceeds repeated.
2900, the new cycles are saved as H : FUL flashes 7 times (for 3 seconds).
2901st cycle, 2902nd cycle ---. Each : flashes 1 time.
time the new cycle is saved, however, 2) If the total number of cycles reaches
the cycle data are deleted from the oldest 9997 (the remaining capacity is 2 cycles
one. (The alarm of "2)" above is main- or less) or the difference between the
tained.) saved integrated pay load and 999900
tons (upper limit) becomes 5 times the
2. Engine ON/OFF data rated hauling capacity, the following is
1) If the number of saved ON/OFF times repeated.
reaches 105 (the remaining capacity is H : FUL lights up (for 3 seconds).
10 times or less), the following is : flashes 1 time.
repeated 2 times and then goes off. 3) If the total number of cycles reaches
E : FUL flashes 7 times (for 3 seconds). 9999 or the saved integrated pay load
: flashes 1 time. exceeds 999900 tons, both of the inte-
2) If the number of saved ON/OFF times grated pay load and total number of
reaches 115 (the remaining capacity is 0 cycles are cleared to 0, and then they are
time), the following is repeated 2 times integrated again. (The display unit dis-
and then goes off. plays the operating time normally again.)
E : FUL lights up (for 3 seconds).
: flashes 1 time. 5. For the method of resetting the data in 1 – 3
3) If the number of saved ON/OFF times above when they become FULL, see "8.3
exceeds 115, the new ON/OFF times are Operator check mode" in the instruction
saved as 116th time, 117th time ---. manual for Payload Meter (Card type).
Each time the new ON/OFF time is Once the data in 4 becomes FULL, it is not
saved, however, the engine ON/OFF reset until it is cleared to 0 automatically. For
data are deleted from the oldest one. the method of clearing this data to 0 forcibly
before it becomes FULL, see "8.2 Forcible
3. Abnormality/Warning data display of integrated pay load/total number of
1) If the number of saved abnormalities/ cycles" in the instruction manual for Payload
warnings reaches 220 (the remaining Meter .
capacity is 10 abnormalities/warnings or
less), the following is repeated. 6. As for the order of display, any priority is not
E : FUL flashes 7 times (for 3 seconds). given to the items in 1 – 4 above. If multiple
: flashes 1 time. data become FULL simultaneously, they are
2) If the number of saved abnormalities/ displayed while the dump truck is not being
warnings reaches 230 (the remaining loaded.
capacity is 0 abnormality/warning), the
following is repeated.
E : FUL lights up (for 3 seconds).
: flashes 1 time.
3) If the number of saved abnormalities/
warnings exceeds 230, the new abnor-
malities/warnings are saved as 231st
abnormality/warning, 232nd abnormality/
warning ---. Each time the new abnor-
mality/warning is saved, however, the
HD465-7, HD605-7 20-805

(1)
(*2) Inaccurate pay load in cycle data

1. The payload meter constantly senses the
pay load by the signals from the suspension
pressure sensor. The sensed pay load
becomes a little inaccurate during and just
after loading because of the dynamic friction
of the suspension. To save the pay load
more accurately, the payload meter senses
and saves the pay load just before dumping
after the dynamic friction of the suspension
during loading is canceled by loaded travel.
(The payload meter saves the payload meter
as a part of the cycle data.)
2. Accordingly, if the load is dumped (if the

dump lever is operated) before pitching of
the machine body stops, the payload meter
may save the pay load inaccurately.
3. When the dump truck is braked sharply or

stopped by chocks in the dumping place, the
pay load may be saved inaccurately.
4. If the load is dumped before the dump truck

stops pitching for the above reasons, the
payload meter displays "Inaccurate pay load
in cycle data" in the abnormality/warning
items list to call the operator's attention. The
pay load sensed in this case is saved, how-
ever.
20-806 HD465-7, HD605-7

(1)

panel panel panel
Problem that
appears on machine

1
• Disconnection
• Ground fault
• Short circuit
indicate priority)
side.
side.
5
side.
HD465-7, HD605-7 20-807

(10)


code code

input

sistency
source (Hot short)
cuit
MW Sliding
NS Overheat
20-808 HD465-7, HD605-7

(10)
TROUBLESHOOTING LC-1
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED

Trouble When starting switch is turned ON, any item is not displayed
Not set Not set Not set
Contents of trouble • When the starting switch is turned ON, any item is not displayed.
Problem that
• When the starting switch is turned ON, any item is not displayed.
appears on machine
• Before performing the troubleshooting, check that fuse BT2 (12) circuit breaker (80 A) is not broken.
Related information
(If the fuse is broken, check its wiring harness for grounding fault.)

When LC GDL relay (R10) is re- No Relay (R10) is normal
placed, is failure repaired? Yes Relay (R10) is defective
3) Check the relay.
1 LC GDL relay (R10) defective Between R10 (male) (5) – (6) Resistance 200 – 400 z
3) Check the relay.
4) Apply voltage between R10 (male) (1) – (2)
Apply 24 V between
Resistance Max. 1 z
Possible causes (3) – (5) Do not apply 24 V be-
and standard value Resistance Min. 1 M z
tween (1) – (2).
in normal state
2) Disconnect connector connectors R10 and fuse BT2 (12).
Wiring harness between battery relay terminal
Disconnection in wiring har- M, fuse BT2 (12) – R10 (female) (1), (5) Resistance Max. 1 z
ness
2 Wiring harness between R10 (female) (2) –
chassis ground
contact)
Resistance Max. 1 z
R10 (female) (3)
Resistance Max. 1 z
chassis ground
2) Disconnect connector PM5.
3 Payload meter defective 4) Connect the connector.
Between PM5 (1) – (13) Voltage 20 – 30 V
HD465-7, HD605-7 20-809

(10)
20-810 HD465-7, HD605-7

(1)
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO
NOT LIGHT UP
Action code Failure code Controller code After starting switch is turned ON, all external pilot lamps do not
light up
Trouble
Not set Not set Not set (Perform troubleshooting with shift lever in N and starting switch
in ON)
• After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
Contents of trouble
shift lever in N and starting switch in ON.)
Problem that • After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
appears on machine shift lever in N and starting switch in ON.)
• Check that any bulb is not broken.
• If there is grounding fault between the fuse and shift lever switch terminal N (on the power supply side),
Related information failure code "DF10KA" related to the transmission controller is displayed.
• Before performing the troubleshooting, check that fuse BT2 (14) is not broken. (If the fuse is broken,
check its wiring harness for grounding fault.)

1 Breakage of bulb Any bulb must not be broken.
When payload meter relay (R40) is No Relay (R40) is normal
replaced, is failure repaired? Yes Relay (R40) is defective
3) Check the relay.
Payload meter relay (R40) 1) Turn the starting switch OFF.

2 2) Disconnect connector R40.
defective
3) Check the relay.
4) Apply voltage between R40 (male) (5) – (6)
Apply 24 V between
Resistance Max. 1 z
Possible causes tween (5) – (6).
and standard value Apply 24 V between
tween (5) – (6).
2) Disconnect connectors SF1, R40, PM5, R43, R44, R45, B1, B2, and
B3.
1) Any lamp does not light up.
Wiring harness between SF1 (female) (4) –
Resistance Max. 1 z
R40 (female) (5)
ness Wiring harness between R40 (female) (6) –
(Disconnection or defective chassis ground
contact) 2) Specific lamps do not light up.
Wiring harness between R40 (female) (2), (4)
Resistance Max. 1 z
– R43 (female) (3)
Resistance Max. 1 z
– R44 (female) (3)
Resistance Max. 1 z
– R45 (female) (3)
HD465-7, HD605-7 20-811

(10)

Wiring harness between R43 (female) (6) – G
Resistance Max. 1 z
(female) (1)
Wiring harness between R44 (female) (6) – A
Resistance Max. 1 z
(female) (1)
Disconnection in wiring har- Wiring harness between R45 (female) (6) – R
Resistance Max. 1 z
ness (female) (1)
3
(Disconnection or defective Wiring harness between B1 (female) (1) –
chassis ground
Wiring harness between B2 (female) (1) –
Resistance Max. 1 z
chassis ground
Wiring harness between B3 (female) (1) –
Resistance Max. 1 z
chassis ground
2) Disconnect connectors SF1, R40, PM5, R43, R44, and R45.
1) Any lamp does not light up.
aIn this case, fuse BT3 (10) (for supplying power to shift switch N)
is broken.
Resistance between
Wiring harness between SF1 (fe- SF1 (female) (4), R40
Possible causes Min. 1 M z
and standard value male) (4) – R40 (female) (5) (female) (5) – chassis
in normal state ground
2) Specific lamps do not light up.
ness
Wiring harness between PM5 (fe- PM5 (female) (4), R43
Max. 1 z
male) (4) – R43 (female) (2) (female) (2) – chassis
ground
Resistance between
Max. 1 z
male) (5) – R44 (female) (2) (female) (2)– chassis
ground
Resistance between
Max. 1 z
ground
5 Payload meter defective 5) Turn the starting switch ON.
20-812 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-813

(1)
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET

Trouble External lamps light up while condition for lighting is not set
Contents of trouble • External lamps light up while condition for lighting is not set.
Problem that
• External lamps light up while condition for lighting is not set.
appears on machine

2) Replace R43, R44, and R45 with normal ones.
(Replace only the defective relays with normal ones.)
When payload meter lamp relays Relays (R43), (R44),
No
(R43), (R44), and (R45) is re- and (R45) are normal
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 2) Disconnect connectors R43, R44, and R45.
1 (R43), (R44), and (R45) de- 3) Check the relays.
fective
Between R43, R44, and R45 (1) – (2) Resistance 200 – 400 z
2) Disconnect connectors R43, R44, and R45.
3) Check the relays.
4) Apply voltage between R43, R44, and R45 (1) – (2).
Apply 24 V between
Resistance Max. 1 z
Between R43, R44, (1) – (2).
Possible causes and R45 (3) – (6). Do not apply 24 V be-
and standard value Resistance Min. 1 M z
tween (1) – (2).
in normal state
2) Disconnect connectors SF1, R40, R43, R44, and R45.
Voltage between SF1
Wiring harness between SF1 (fe- (female) (4), R40 (fe-
Max. 1 V
male) (4) – R40 (female) (5) male) (5) – chassis
ground
Voltage between PM5
Wiring harness between R40 (fe- (female) (4), R43 (fe-
2 Hot short in wiring harness Max. 1 V
male) (2), (4) – R43 (female) (3) male) (2) – chassis
ground
Voltage between PM5
Max. 1 V
ground
Voltage between PM5
Max. 1 V
ground
20-814 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-815

(1)
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL

Trouble Lighting level of external pilot lamps is abnormal
Contents of trouble • Lighting level of external pilot lamps is abnormal.
Problem that
• Lighting level of external pilot lamps is abnormal.
appears on machine
Related information • If this phenomenon is stopped by performing calibration again, it is not a failure.

4) Set the shift lever in N.
No
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 1) Turn the starting switch OFF.
1 (R43), (R44), and (R45) de- 2) Disconnect connectors R43, R44, and R45.
fective 3) Check the relays.
Between R43, R44, and R45 (1) – (2) Resistance 200 – 400 z
Apply 24 V between
Resistance Max. 1 z
Between R43, R44, (1) – (2).
and R45 (3) – (6). Do not apply 24 V be-
tween (1) – (2).
Possible causes
in normal state 2) Disconnect connectors PM5, R43, R44, and R45.
Disconnection in wiring har- Wiring harness between PM5 (female) (4) –
2 R43 (female) (2)
R44 (female) (2)
Resistance Max. 1 z
R45 (female) (2)
2) Disconnect connectors R40, R43, R44, R45, G, A, and R.
Voltage between R43
Wiring harness between R43 (fe- (female) (6), G (fe-
Max. 1 V
male) (6) – G (female) (1) male) (1) – chassis
ground
3 Hot short in wiring harness Voltage between R44
Wiring harness between R44 (fe- (female) (6), A (fe-
Max. 1 V
male) (6) – A (female) (1) male) (1) – chassis
ground
Voltage between R45
Wiring harness between R45 (fe- (female) (6), R (fe-
Max. 1 V
male) (6) – R (female) (1) male) (1) – chassis
ground
20-816 HD465-7, HD605-7

(10)

in normal state 5 Payload meter defective 5) Turn the starting switch ON.
HD465-7, HD605-7 20-817

(10)
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED

(CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED)
Action code Failure code Controller code Cycle data and engine ON/OFF data not recorded
Trouble
Not set Not set Not set (Charge level signal system: Judges that engine is stopped)
• Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
Contents of trouble
is stopped.)
Problem that • Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
appears on machine is stopped.)
Related information • If the engine ON/OFF data are recorded, perform troubleshooting of LC-7.

Disconnection in wiring har- 3) Insert T-adapter.
1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) (9) – alternator terminal R (9) – chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 (9) – chassis ground Voltage Min. 5 V
20-818 HD465-7, HD605-7

(10)
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT

CONFORM TO CONDITION
(SHIFT LEVER "N" POSITION SIGNAL SYSTEM)
Action code Failure code Controller code Calibration cannot be performed and displayed clock does not
Trouble conform to condition
Not set Not set Not set (Shift lever "N" position signal system)
• Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
Contents of trouble
position signal system)
Problem that • Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
appears on machine position signal system)
Related information • Check that the external pilot lamp operates as described in the operation manual.

When transmission neutral relay No Relay (R02) is normal
(R02) is replaced with normal one,
is failure repaired? Yes Relay (R02) is defective
Transmission neutral relay 3) Check the relays.
1
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
2) Disconnect connectors PM5 and R02.
Possible causes Disconnection in wiring har- Wiring harness between PM6 (female) (10) –
and standard value
in normal state 2 R02 (female) (6)
Wiring harness between SF1 (female) (4) –
R02 (female) (1)
Resistance Max. 1 z
– chassis ground
2) Disconnect connectors BRC3B and PM3.
Resistance between
Wiring harness between PM6 (fe- PM6 (female) (10),
Ground fault in wiring har- Min. 1 M z
3 male) (10) – R02 (female) (6) R02 (female) (6) –
ness
chassis ground
Resistance between
Wiring harness between SF1 (fe- SF1 (female) (4), R02
Min. 1 M z
ground
Between PM6 When shift lever is N Voltage 20 – 30 V
(10) – PM5 (13) When shift lever is not N Voltage Max. 1.5 V
HD465-7, HD605-7 20-819

(10)
20-820 HD465-7, HD605-7

(1)
LC-7 DISPLAYED LOGIC IS ABNORMAL

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go off.
Action code Failure code Controller code Displayed logic is abnormal

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer
Trouble
Not set Not set Not set does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go
off.
• When loaded dump truck starts traveling, "0" is kept displayed.
Contents of trouble • After loaded dump truck start traveling, display of odometer does not increase.
• When travel speed exceeds limit speed, "SP:SP" does not go off.
• When loaded dump truck starts traveling, "0" is kept displayed.
Problem that
• After loaded dump truck start traveling, display of odometer does not increase.
appears on machine
• When travel speed exceeds limit speed, "SP:SP" does not go off.
• If the pay load is displayed during loading but "0" is displayed after the dump truck starts traveling until
it dumps the load, the travel speed signal is not sensed.
Related information
• If failure codes "DLT3KA" and "DLT3LC" related to transmission controller or failure codes "DLT3KA"
and "dLT3LC" related to retarder controller are displayed, perform troubleshooting for them first.

2) Disconnect connectors PM5 and R02.
ness
1 Wiring harness between PM5 (female) (7) –
Possible causes (Disconnection or defective Resistance Max. 1 z
CN5 (female) (1)
and standard value contact)
CN5 (female) (2)
2 Payload meter defective 3) Connect T-adapter.
Wiring harness between PM5 (female) (7) – (8) Resistance Max. 1 z
HD465-7, HD605-7 20-821

(10)
d) Integrated pay load is not displayed.

Trouble
Not set Not set Not set d) Integrated pay load is not displayed.
Contents of trouble • Integrated pay load is not displayed.
Problem that
• Integrated pay load is not displayed.
appears on machine
• To display the integrated pay load, the following condition must be satisfied during the time from the
start to the end of dumping.
(1) When the load was dumped previous time, it was reduced to below 1/5 of the rated pay load within
5 minutes after the dump lever was changed from "LOWER" to "FLOAT".
Related information
(2) When the load was dumped previous time, "b-fl" was not displayed for 5 seconds just after the
dump lever was changed from "LOWER" to "FLOAT".
(3) The load to be dumped this time is above 1/2 of the rated pay load.
• If the payload meter displays "b-fl", perform troubleshooting of LC-8.

and standard value
in normal state 1 If the payload meter displays "b-FL", perform troubleshooting of LC-8.
20-822 HD465-7, HD605-7

(10)
e) Displayed and saved pay load is not correct.

Trouble
Not set Not set Not set e) Displayed and saved pay load is not correct.
Contents of trouble • Displayed and saved pay load is not correct.
Problem that
• Displayed and saved pay load is not correct.
appears on machine
• The error of the payload meter is ± 5%.
• The possible causes of display of wrong displayed and saved values are as follows
(1) Defective setting of model selection switch of payload meter
(2) Defective adjustment of suspension
(3) Negligence of calibration of payload meter
Related information <Precautions>
i) If the load is dumped while the displayed pay load is changing because of pitching of the truck body,
the saved value may become inaccurate. Accordingly, dump after the displayed value is fixed.
ii) The pay load displayed in the loading place (just after loading) may be a little (1 - 5 t) less than that
displayed in the dumping place.
aFor details, see Operation Manual, 3. For higher accuracy.

LC display: "CO: X. X"
HD465-7 HD605-7
1 Wrong model setting
X. X
0. 7 0. A
display
i) When truck is empty
(1) Empty, (2) Flat place
aSee STRUCTURE AND OPERATION, Service Check Mode, (b)
Display of data for calculation of pay load.
Pressure difference between both sides
Possible causes 0.98 MPa {10 kg/cm2}
(Front)
and standard value
in normal state Pressure difference between both sides (Rear) 1.47 MPa {15 kg/cm2}
Improper suspension gas • If the pressure difference exceeds the above range, adjust the sus-
2
pressure pension gas, referring to "Testing and adjusting suspension cylin-
der".
ii) When truck is loaded
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
iii)When truck turns on slope
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
3 Improper calibration • Perform calibration according to the operation manual.
HD465-7, HD605-7 20-823

(10)
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL"

(BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION
WHILE TRUCK IS NOT DUMPING)
Action code Failure code Controller code Payload meter keeps displaying "b:FL"
Trouble (Body "FLOAT" signal system: Dump lever is not in "FLOAT" po-
Not set Not set Not set sition while truck is not dumping)
• Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
Contents of trouble
position while truck is not dumping)
Problem that • Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
appears on machine position while truck is not dumping)
• Check that failure codes "DK52KX", "DK53L8", and "DK24KX" (failure in dump lever system) related
Related information
to retarder controller are not displayed. If any of them is displayed, perform troubleshooting for it.

Disconnection in wiring har- 2) Disconnect connectors PM6 and BRC1.
1
BRC1 (female) (15)
2) Disconnect connectors PM6 and BRC1.
ness
Min. 1 M z
male) (9) – BRC1 (female) (15) BRC1 (female) (15) –
chassis ground
and standard value 2) Disconnect connector BRC1.
3 Retarder controller defective 5) Turn the starting switch ON.
Between BRC1 Dump lever is in "FLOAT". Voltage 20 – 30 V

(15) – chassis Dump lever is out of
ground Voltage Max. 1 V
"FLOAT".
4 Payload meter defective 5) Turn the starting switch ON.
Between PM6 Dump lever is in "FLOAT". Voltage 20 – 30 V
(9) – chassis Dump lever is out of
"FLOAT".
20-824 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-825

(1)
TROUBLESHOOTING LC-9, LC-10
LC-9 PAYLOAD METER DISPLAYS "F:09"

(LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)

Payload meter displays "F:09"
Payload meter Trouble
Not set Not set (Lowering of internal backup battery voltage)
displays "F:09"
Contents of trouble • Payload meter displays "F:09" (Lowering of internal backup battery voltage)
Problem that
• Payload meter displays "F:09" (Lowering of internal backup battery voltage)
appears on machine

and standard value Lowering of internal backup
in normal state 1 Replace the internal backup battery according to the operation manual.
battery voltage
LC-10 PAYLOAD METER DISPLAYS " :FULL"

(DATA SAVING MEMORY IS FULL)

Payload meter Payload meter displays " :FULL"
Trouble
Not set displays Not set (Data saving memory is full)
" :FULL"
Contents of trouble • Payload meter displays " :FULL". (Data saving memory is full.)
Problem that
• Payload meter displays " :FULL". (Data saving memory is full.)
appears on machine

Cycle data saving memory
• Download the data to a personal computer and clear the memory to
1 full
"0" (zero ) according to the operation manual.
a"L. FULL" is displayed
Engine ON/OFF data saving
2 memory full
Possible causes "0" (zero ) according to the operation manual.
a"E. FULL" is displayed
and standard value
in normal state Failure and warning data
3 saving memory full
"0" (zero ) according to the operation manual.
a"F. FULL" is displayed
Integrated pay load and total
number of cycles data sav- • Download the data to a personal computer and clear the memory to
4
ing memory full "0" (zero ) according to the operation manual.
a"F. FULL" is displayed
20-826 HD465-7, HD605-7

(10)
LC-11 PAYLOAD METER DISPLAYS "F-20"

: FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND
CLINOMETER SYSTEM
Action code Failure code Controller code LC-11 Payload meter displays "F-20"
Payload meter Trouble : Failure in power source of suspension pressure sensor and cli-
Not set Not set nometer system
displays "F-20"
Contents of trouble • The sensor power source output is below 15 V while the source voltage is above 20 V.
Action of controller • All the external pilot lamps flash.
Problem that • Pay load is not displayed correctly.
appears on machine • Operation data is not saved correctly.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, SURR, and PM3.
Resistance between
Min. 1 M z
male) (2) – SUFL (female) (B) SUFL (female) (B) –
chassis ground
Resistance between
Min. 1 M z
male) (2) – SUFR (female) (B) SUFR (female) (B) –
chassis ground
ness
Min. 1 M z
male) (2) – SURL (female) (B) SURL (female) (B) –
chassis ground
Resistance between
Min. 1 M z
male) (2) – SURR (female) (B) SURR (female) (B) –
chassis ground
Resistance between
Possible causes
Wiring harness between PM6 (fe- PM6 (female) (2), PM3
and standard value Min. 1 M z
male) (2) – PM3 (female) (C) (female) (C) – chassis
in normal state
ground
2) Replace the sensor.
When front left suspension pressure sensor is Front left sensor is de-
replaced, the error is corrected. fective.
When front left suspension pressure sensor is Front left sensor is
replaced, the error is not corrected. normal.
When front right suspension pressure sensor Front right sensor is
is replaced, the error is corrected. defective.
2 When front right suspension pressure sensor Front right sensor is
defective
is replaced, the error is not corrected. normal.
When rear left suspension pressure sensor is Rear left sensor is de-
When rear left suspension pressure sensor is Rear left sensor is nor-
replaced, the error is not corrected. mal.
When rear right suspension pressure sensor is Rear right sensor is
replaced, the error is corrected. defective.
When Rear right suspension pressure sensor Rear right sensor is
HD465-7, HD605-7 20-827

(10)

3 Clinometer sensor defective When the clinometer is replaced, the error is Clinometer is defec-
Possible causes corrected. tive.
and standard value When the clinometer is replaced, the error is
in normal state Clinometer is normal.
not corrected.
4 Payload meter defective 3) Connect T-adapter (only payload meter side).
Between PM6 (male) (2) – (3) Voltage 18 ± 3 V
20-828 HD465-7, HD605-7

(10)
LC-12 PAYLOAD METER DISPLAYS "F-21" – "F-24"

: DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL
SYSTEM
Payload meter displays "F-21" – "F-24"
Payload meter Trouble : Disconnection or grounding fault in suspension sensor signal
Not set displays Not set system
"F-21" – "F-24"
Contents of trouble • Input signal of suspension pressure sensor is below 1 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR.
Resistance Max. 1 z
SUFL (female) (B)
Resistance Max. 1 z
SUFR (female) (B)
Resistance Max. 1 z
SURL (female) (B)
Resistance Max. 1 z
SURR (female) (B)
Disconnection in wiring har- SUFL (female) (C) Resistance Max. 1 z
ness
1 Wiring harness between PM6 (female) (5) –
SUFR (female) (C)
contact)
Resistance Max. 1 z
SURL (female) (C)
Resistance Max. 1 z
SURR (female) (C)
Resistance Max. 1 z
SUFL (female) (A)
Possible causes
in normal state SUFR (female) (A)
Resistance Max. 1 z
SURL (female) (A)
Resistance Max. 1 z
SURR (female) (A)
2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Resistance between
Min. 1 M z
male) (4) – SUFL (female) (C) SUFL (female) (C) –
chassis ground
Resistance between
Ground fault in wiring har- Min. 1 M z
2 male) (5) – SUFR (female) (C) SUFR (female) (C) –
ness
chassis ground
Resistance between
Min. 1 M z
male) (6) – SURL (female) (C) SURL (female) (C) –
chassis ground
Resistance between
Min. 1 M z
male) (7) – SURR (female) (C) SURR (female) (C) –
chassis ground
HD465-7, HD605-7 20-829

(10)

defective
Possible causes When rear left suspension pressure sensor is Rear left sensor is nor-
and standard value replaced, the error is not corrected. mal.
in normal state
When Rear right suspension pressure sensor Rear right sensor is
2) Disconnect connectors PM5 and PM6.
4 Payload meter defective Between PM6 (2) – (3) Voltage 18 ± 3 V
Between PM6 (4) – (3) Voltage 1–5V
20-830 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-831

(1)
LC-13 PAYLOAD METER DISPLAYS "F-25" – "F-28"

: SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN SUSPENSION
SENSOR SIGNAL SYSTEM

Payload meter displays "F-25" – "F-28"
Payload meter
Trouble : Short circuit with power source (Hot short) in suspension sensor
Not set displays Not set signal system
"F-25" – "F-28"
Contents of trouble • The suspension pressure input signal is above 5 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Voltage between PM6
Wiring harness between PM6 (fe- (female) (4), SUFL (fe-
Max. 1 V
male) (4) – SUFL (female) (C) male) (C) and chassis
ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (5), SUFR
male) (5) – SUFR (female) (C) (female) (C) and chas-
sis ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (6), SURL (fe-
Max. 1 V
male) (6) – SURL (female) (C) male) (C) and chassis
ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (7), SURR
Max. 1 V
Possible causes male) (7) – SURR (female) (C) (female) (C) and chas-
and standard value sis ground
defective
20-832 HD465-7, HD605-7

(10)

and standard value
in normal state 3 Payload meter defective Between PM6 (2) – (3) Voltage 18 ± 3 V
HD465-7, HD605-7 20-833

(10)
LC-14 PAYLOAD METER DISPLAYS "F-CAL"

(NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)

Payload meter Payload meter displays "F-CAL"
Trouble
Not set displays Not set (Negligence of calibration or internal damage of payload meter)
"F-CAL"
Contents of trouble • Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
Problem that
• Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
appears on machine

Possible causes Negligence of calibration or
and standard value internal damage of payload
in normal state 1 • Repair according to the operation manual.
meter
a"F-CAL" is displayed.
20-834 HD465-7, HD605-7

(10)
LC-15 PAYLOAD METER DISPLAYS "F:43" – "F:45"

(SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN EXTERNAL PILOT
LAMP RELAY SYSTEM)
Action code Failure code Controller code Payload meter displays "F:43" – "F:45"
Trouble
Not set Not set Not set (Short circuit with power source in external pilot lamp relay system)
Contents of trouble • There is short circuit with power source (Hot short) in external pilot lamp relay system.
Problem that • There is short circuit with power source (Hot short) in external pilot lamp relay system.
appears on machine • Payload meter displays "F:43" – "F:45".

No
Payload meter lamp relays placed with normal ones respec- Relays (R43), (R44),
Yes
(R43), (R44), and (R45) de- tively, is failure repaired? and (R45) are defective
fective 1) Turn the starting switch OFF.
aWhen "F:43" is displayed, 2) Disconnect connectors R43, R44, and R45.
1 R43 is defective. 3) Check the relays.
aWhen "F:44" is displayed,
R44 is defective. Between R43, R44, and R45 (1) – (2) Resistance 200 – 400 z
aWhen "F:45" is displayed, 1) Turn the starting switch OFF.
R45 is defective. 2) Disconnect connectors R43, R44, and R45.
Possible causes
Resistance Max. 1 z
in normal state Between R43, R44, (1) – (2).
and R45 (3) – (6). Do not apply 24 V be-
tween (1) – (2).
2) Disconnect connectors PM5, R40, R43, R44, and R45.
Hot short in wiring harness Voltage between PM5
aWhen "F:43" is displayed, Wiring harness between PM5 (fe- (female) (4), R43 (fe-
R43 system is short-cir- Max. 1 V
cuited. ground
aWhen "F:44" is displayed,
2 Voltage between PM5
R44 system is short-cir-
cuited. Wiring harness between PM5 (fe- (female) (5), R44 (fe-
Max. 1 V
aWhen "F:45" is displayed, male) (5) – R44 (female) (2) male) (2) – chassis
R45 system is short-cir- ground
cuited. Voltage between PM5
Wiring harness between PM5 (fe- (female) (6), R45 (fe-
Max. 1 V
ground
HD465-7, HD605-7 20-835

(10)

2) Disconnect connectors R40, R43, R44, and R45.
Voltage between PM5
Max. 1 V
ground
3 Hot short in wiring harness Voltage between PM5
Max. 1 V
Possible causes ground
and standard value Voltage between PM5
in normal state Wiring harness between PM5 (fe- (female) (6), R45 (fe-
Max. 1 V
ground
Payload meter defective 1) Turn the starting switch OFF.
aWhen "F:43" is displayed, 2) Disconnect connector PM5.
PM5 (4) system is defec- 3) Insert T-adapter.
tive. 4) Connect the connector.
aWhen "F:44" is displayed, 5) Turn the starting switch ON.
4
PM5 (5) system is defec-
Between PM 5 (4) – (13) Voltage 20 – 30 V
tive.
aWhen "F:45" is displayed, Between PM 5 (5) – (13) Voltage 20 – 30 V
PM5 (6) system is defec-
tive. Between PM 5 (6) – (13) Voltage 20 – 30 V
20-836 HD465-7, HD605-7

(10)
LC-16 PAYLOAD METER DISPLAYS "L-bad"

(CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)
Action code Failure code Controller code Payload meter displays "L-bad"
Trouble
Not set Not set Not set (Cycle data were saved while truck body was pitching)
Contents of trouble • Since truck pitches during dumping, the pay load in the cycle data is not correct.
Problem that
• Since truck pitches during dumping, the pay load in the cycle data is not correct.
appears on machine
• The pay load must be calculated accurately and saved as a cycle data when the truck dumps. If the
truck pitches when it dumps, the calculation accuracy is lowered. Pitching of the truck during dumping
is notified to the operator by "L-bad". Accordingly, wait for 5 seconds after the truck stops, and then
Related information start dumping.
• If "L-bad" is displayed during dumping, it is maintained until the empty truck starts traveling.
• If "L-bad" is always displayed and the pay load in the cycle data is abnormal, perform the following trou-
bleshooting.

2) Disconnect connectors PM5, PM6, SUFL, SUFR, SURL, and SURR.
Resistance Max. 1 z
SUFR (female) (A)
1 SUFL (female) (C)
SUFR (female) (C)
Resistance Max. 1 z
SURL (female) (C)
Resistance Max. 1 z
SURR (female) (C)
Possible causes 2) Replace the sensor.
and standard value 3) Turn the starting switch ON.
in normal state When front left suspension pressure sensor is Front left sensor is de-
defective
HD465-7, HD605-7 20-837

(10)

and standard value
in normal state 3 Payload meter defective Between PM6 (2) – (3) Voltage 18 ± 3 V
20-838 HD465-7, HD605-7

(10)
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
Action code Failure code Controller code External pilot lamp indicates forecast while truck is not being
Trouble loaded or clock is displayed while truck travels for 160 m after it
Not set Not set Not set is loaded
• External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
Contents of trouble
travels for 160 m after it is loaded
Problem that • External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
appears on machine travels for 160 m after it is loaded

and standard value
in normal state 1 Improper calibration • Perform calibration according to the operation manual.
HD465-7, HD605-7 20-839

(10)

: GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL
SYSTEM
Action code Failure code Controller code Payload meter displays "F-31"
Payload meter Trouble : Grounding fault or disconnection in clinometer sensor signal
Not set Not set system
displays "F-31"
Contents of trouble • The signal circuit voltage of the clinometer sensor is below 1.6 V.
• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

1 PM3 (female) (B)
PM3 (female) (C)
Resistance Max. 1 z
PM3 (female) (A)
ness
Possible causes Wiring harness between PM6 (fe- PM6 (female) (8), PM3
Min. 1 M z
and standard value male) (8) – PM3 (female) (B) (female) (B) – chassis
in normal state ground
3 Clinometer sensor defective When the clinometer is replaced, error is cor- Clinometer is defec-
rected. tive.
When the clinometer is replaced, error is not
Clinometer is normal.
corrected.
Between PM6 (2) – (3) Voltage 18 ± 3 V
Between PM6 (8) – (3) Voltage 1.6 – 3.6 V
20-840 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-841

(1)

: SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL
SYSTEM

Payload meter Trouble Payload meter displays "F-32"
Not set Not set
displays "F-32"
Contents of trouble • The signal circuit voltage of the clinometer sensor is above 3.6 V.
• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

Voltage between PM6
Wiring harness between PM6 (fe- (female) (8), PM3 (fe-
Max. 1 V
male) (8) – PM3 (female) (B) male) (B) – chassis
ground
Possible causes 2) Disconnect connector PM3.
and standard value 3) Insert T-adapter.
in normal state 2 Clinometer sensor defective 4) Connect the connector.
Between PM3 (C) – (A) Voltage 18 ± 3 V
Between PM3 (B) – (A) Voltage 1.6 – 3.6 V
3 Payload meter defective 4) Connect the connectors.
Between PM6 (2) – PM5 (13) Voltage 18 ± 3 V
Between PM6 (8) – PM5 (13) Voltage 1.6 – 3.6 V
20-842 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-843

(1)
LC-20 PAYLOAD METER DISPLAYS "F:18"

(DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)
Action code Failure code Controller code Payload meter displays "F:18"
Trouble
Not set Not set Not set (Disconnection in charge level signal system)
Contents of trouble • There is disconnection in the charge level signal system.
Problem that • There is disconnection in the charge level signal system.
appears on machine • Payload meter displays "F:18".
• If failure code "AB00MA" (Malfunction of alternator) related to transmission controller is displayed, per-
Related information
form troubleshooting for it first.

1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) (9) – alternator terminal R (9) – chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 (9) – chassis ground Voltage Min. 5 V
20-844 HD465-7, HD605-7

(10)
TROUBLESHOOTING FOR
MONITOR SYSTEM
(MON MODE)
Electrical system diagram related to monitor .............................................................................................. 20-904

Information in troubleshooting table........................................................................................................ 20-905
Phenomenon 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, warning 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 warning 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 warning 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

(10)
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
a For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM
Mode).
20-902 HD465-7, HD605-7

(5)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

20-904 HD465-7, HD605-7

(2)

panel panel panel
Problem that
appears on machine

1
• Disconnection
• Ground fault
• Short circuit
indicate priority)
side.
side.
5
side.
HD465-7, HD605-7 20-905

(10)


code code

input

sistency
source (Hot short)
cuit
MW Sliding
NS Overheat
20-906 HD465-7, HD605-7

(10)
TROUBLESHOOTING [B@C7NS], [B@CENS]
[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS)
Action code Failure code Controller code Rear brake oil: Overheating (NS)
Trouble
E02 B@C7NS MON (Brake cooling oil overheating)
Contents of trouble • Brake cooling oil is overheating.
Problem that
• If the machine is used without repairing, the rear brake may be broken.
appears on machine
Related information • This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of brake cool-
1
and standard value ing oil
in normal state
• If the brake cooling oil is not overheating, the machine monitor is de-
fective.
[B@CENS] TORQUE CONVERTER: OVERHEATING (NS)

Trouble Torque converter: Overheating (NS)
E02 B@CENS MON
Contents of trouble • Torque converter is overheating
Problem that
• If the machine is used without repairing, the torque may be broken.
appears on machine
Related information • This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of torque con-
1
and standard value verter
in normal state
• If the torque converter is not overheating, the machine monitor is de-
fective.
HD465-7, HD605-7 20-907

(10)
TROUBLESHOOTING [DAF0KM]
[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)

Action code Failure code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF0KM MON (Disagreement of optional settings)
• The optional settings of the rotary switch and dip switch on the rear side of the machine monitor do not
Contents of trouble
agree with the signals of the optional setting connector.
• The controller maintains the abnormal state until the starting switch is turned OFF.
• The controller does not recognize the functions (If equipped), the settings of which do not agree the
signals.
• The controller does not record this failure in the fault history.
Problem that
• Some functions (If equipped) do not work.
appears on machine
• Connections of wiring harnesses OP1–OP7 depend on the specification. For details, see "Adjustment
of machine monitor".
• This failure can be checked with SW1–3 (monitor code: 30800), SW5–1, 5–2 (monitor code: 30900),
Related information SW5–3, 5–4 (monitor code: 30901), SW6–1, 6–2 (monitor code: 30902), SW6–3, and 6–4 (monitor
code: 30903) on the rear side of the machine monitor.
• This failure can be checked with optional selection connectors OP1, 2 (monitor code: 31000), OP3, 4
(monitor code: 31001), and OP5, 6 (monitor code: 31002).

2) Disconnect connector DPC3A.
Resistance between
When connected
Wiring harness (CLOSED) DPC3A (female) (4) – Max. 1 z
between DPC3A chassis ground
(female) (4) – When discon- Resistance between
OP1 (female) (1) nected DPC3A (female) (4) – Min. 1 M z
(OPENED) chassis ground
Resistance between
When connected
Possible causes
and standard value Resistance between
Ground fault in wiring har- When connected
in normal state 1 Wiring harness (CLOSED) DPC3A (female) (7) – Max. 1 z
ness
Resistance between
When connected
OP4 (female) (1) nected DPC3A (female) ((13) Min. 1 M z
(OPENED) – chassis ground
Resistance between
When connected
20-908 HD465-7, HD605-7

(10)

Resistance between
When connected
Ground fault in wiring har- (OPENED) chassis ground
1
When connected
When connected
Resistance between (CLOSED) Resistance Max. 1 z
DPC3A (female) (4) –
When disconnected
chassis ground Resistance Min. 1 M z
(OPENED)
When connected
Possible causes Resistance between (CLOSED) Resistance Max. 1 z
and standard value DPC3A (female) (6) –
When disconnected
in normal state chassis ground Resistance Min. 1 M z
(OPENED)
When connected
When disconnected
(OPENED)
2 Machine monitor defective When connected
When disconnected
(OPENED)
When connected
When disconnected
(OPENED)
When connected
When disconnected
(OPENED)
When connected
When disconnected
(OPENED)
HD465-7, HD605-7 20-909

(10)
20-910 HD465-7, HD605-7

(1)
[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)
Action code Failure code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF9KM MON (Wrong connection of connector)
Contents of trouble • The check signal of the connector does not agree with the internal setting of the machine monitor.
• The controller does not record this failure in the fault history.
• The machine monitor mode select switch does not work.
Problem that
• The optional functions do not work.
appears on machine
• The head lamp HIGH pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.

The connector check signal connectors are connected normally.
1 aConnector check signal connectors: DPC3A (5) (OPEN), DPC2A (5)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector DPC2A.
2
Wiring harness between fuse terminal BT4 (2)
– DPC2A (female) (5)
and standard value 2) Disconnect connector DPC3A.
3 ness Wiring harness between DPC3A (female) (5) –
(Grounding fault of terminal) chassis ground
aThis must not occur basically, since the wiring harness is not con-
nected.
4 Machine monitor defective 3) Connect T-adapter.
Resistance between DPC2A (female) (5) –
chassis ground
HD465-7, HD605-7 20-911

(10)
TROUBLESHOOTING [DAFSKQ]
[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)

Trouble Monitor panel: Disagreement of model selection signals (KQ)
E03 DAFSKQ MON
• Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or the rotary switch of the transmission controller is not set normally.
• The controller controls the truck as HD465-7.
Problem that • None of the meters and gauges display.
appears on machine • Some panel switches and lamps do not work.
Related information • If another failure code "DAQAKQ" is displayed, perform troubleshooting for it.

Communication circuit de-
1 Perform troubleshooting for "DAQSKR".
fective
Possible causes aIf the failure is not repaired by replacing the machine monitor, the
and standard value machine monitor is defective.
in normal state aWhen replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
Transmission controller de- aIf the failure is not repaired by replacing the machine monitor, the
3
fective transmission controller is defective.
20-912 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQSKR]
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CON-

TROLLER AND MACHINE MONITOR) (KR)
Action code Failure code Controller code S-NET communication defective (KR)
Trouble
E03 DAQSKR MON (Between transmission controller and machine monitor)
Contents of trouble • Communication (S-NET) information cannot be obtained from the transmission controller.
Action of controller • The controller maintains the condition at the time when the failure occurs.
Problem that • The meters, gauges, warning lamps, and special functions that obtain information from the transmis-
appears on machine sion controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z
Between each couple of JCD (male) terminals Resistance Max. 1 z
Between each couple of JCE (male) terminals Resistance Max. 1 z
Between each couple of JCF (male) terminals Resistance Max. 1 z
Between each couple of JCG (male) terminals Resistance Max. 1 z
2) Disconnect connectors DPC4, ATC4, and BRC4.
Wiring harness between DPC4 (female) (1) –
Resistance Max. 1 z
ATC4 (female) (12)
Disconnection in wiring har- ATC4 (female) (6) Resistance Max. 1 z
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) (4) – Resistance Max. 1 z
contact) ATC4 (female) (10)
ATC4 (female) (10)
and standard value
in normal state aIf another controller also has an error in S-NET communication, per-
form troubleshooting from the wiring harness.
aDisconnect the connectors to which the S-NET signals of all the con-
trollers connected to S-NET are allotted.
Between DPC4 (female) (1), (2) – chassis
Ground fault in wiring har- Resistance Min. 1 M z
3 ground
ness
aIf another controller also has an error in S-NET communication, per-
4 Hot short in wiring harness Voltage Max. 1 V
ground
HD465-7, HD605-7 20-913

(10)

and standard value Transmission controller de- Between ATC4 (6) – (10) Voltage 6–9V
in normal state 5
fective Between ATC4 (12) – (10) Voltage 6–9V
aIf any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the transmission
controller and check that the transmission controller is outputting the
normal voltage.
20-914 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-915

(2)
TROUBLESHOOTING [DASRKR]
[DASRKR] CAN COMMUNICATION/COMMUNICATION DEFECTIVE: ABNORMALITY IN

OBJECTIVE COMPONENT (KR)
Action code Failure code Controller code CAN communication/Communication defective: Abnormality in
Trouble objective component (KR)
E03 DASRKR MON (Between engine controller and machine monitor)
Contents of trouble • Communication (CAN) information cannot be obtained from the engine controller.
Problem that • The meters, gauges, warning lamps, and special functions that obtain information from the engine con-
appears on machine troller do not operate or display.
Related information

2) Disconnect connector JC14.
1 Junction connector defective 3) Connect T-adapter.
Between JC14 (male) (2) – (8) Resistance Max. 1 z
Between JC14 (male) (4) – (6) Resistance Max. 1 z
2) Disconnect connectors DPC4 and ECMB.
DPC4 (female) (8)
2 Wiring harness defective
aCheck that terminal resistors CAN and CAN2 are connected. The
resistance of each terminal resistor is 120 z.
aCheck that a personal computer or a controller is not connected to
CAN1.
Possible causes aIf VHMS is connected, disconnect it.
and standard value
2) Replace the engine controller.
3 Engine controller defective Engine controller is
When the engine controller is re- No
normal.
placed, does communication be-
come normal? Engine controller is
Yes
defective.
2) Replace the machine monitor.
Machine monitor is
When the machine monitor is re- No
4 Machine monitor defective normal.
placed, does communication be-
come normal? Machine monitor is de-
Yes
fective
aWhen replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
20-916 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DASRKR]
HD465-7, HD605-7 20-917

(1)
TROUBLESHOOTING [DB1SKR]
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROL-

LER AND MACHINE MONITOR) (KR)
Action code Failure code Controller code S-NET communication defective (KR)
Trouble
E03 DB1SKR MON (Between retarder controller and machine monitor)
Contents of trouble • Communication (S-NET) information cannot be obtained from the retarder controller.
Problem that • The meters, gauges, warning lamps, and special functions that obtain information from the retarder
appears on machine controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z
Between each couple of JCD (male) terminals Resistance Max. 1 z
Between each couple of JCE (male) terminals Resistance Max. 1 z
Between each couple of JCF (male) terminals Resistance Max. 1 z
Between each couple of JCG (male) terminals Resistance Max. 1 z
Resistance Max. 1 z
BRC4 (female) (12)
Disconnection in wiring har- BRC4 (female) (6) Resistance Max. 1 z
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) (4) – Resistance Max. 1 z
contact) BRC4 (female) (10)
BRC4 (female) (10)
and standard value
in normal state aIf another controller also has an error in S-NET communication, per-
Ground fault in wiring har- Resistance Min. 1 M z
3 ground
ness
4 Hot short in wiring harness Voltage Max. 1 V
ground
20-918 HD465-7, HD605-7

(10)

and standard value
in normal state 5 Retarder controller defective Between BRC4 (6) – (10) Voltage 6–9V
Between BRC4 (12) – (10) Voltage 6–9V
aIf any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the retarder control-
ler and check that the retarder controller is outputting the normal
voltage.
HD465-7, HD605-7 20-919

(10)
20-920 HD465-7, HD605-7

(2)
TROUBLESHOOTING [DV00KB]
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT: SHORT CIRCUIT (KB)

Trouble Short circuit in alarm buzzer output: Short circuit (KB)
E01 DV00KB MON
Contents of trouble • There is short circuit with the power source in the output circuit of the alarm buzzer.
• The controller turns the output circuit of the alarm buzzer OFF.
Problem that
• The alarm buzzer does not sound.
appears on machine

2) Disconnect connectors DPC1 and BZ2.
Voltage between
Wiring harness between DPC1 DPC1 (female) (13),
Max. 1 V
(female) (13) – BZ2 (female) (2) BZ2 (female) (2) –
Possible causes
chassis ground
and standard value
2) Disconnect connector BZ2 (2) and remove the buzzer.
3) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2 (male) (2).
2 Alarm buzzer defective The alarm buzzer sounds. Alarm buzzer is normal.
The alarm buzzer does not sound. Alarm buzzer is defective.
aCheck the alarm buzzer unit.
• If the results of 1) and 2) above are normal, the machine monitor is
defective.
HD465-7, HD605-7 20-921

(10)
TROUBLESHOOTING MON-1
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT
DISPLAY ANY ITEM
Action code Failure code Controller code When starting switch is turned ON, machine monitor does not
Trouble
Not set Not set MON display any item
Contents of trouble • When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
Problem that
• When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
appears on machine
Related information • Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not
broken.

Disconnection in wiring har- Wiring harness between battery Voltage between BT2
20 – 30 V
ness relay B – fuse BT2 (1) (1) and chassis ground
1
(Disconnection or defective Voltage between
contact) Wiring harness between fuse BT2
DPC1 (6), (7) and 20 – 30 V
(2) – DPC1 (female) (6), (7)
chassis ground
and standard value 2) Disconnect connectors DPC4 and BRC4.
Wiring harness between DPC1 (9), (10) –
Resistance Max. 1 z
chassis ground
Between DPC1(6), (7) – (9), (10) Voltage 20 – 30 V
20-922 HD465-7, HD605-7

(10)
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES
NOT OPERATE NORMALLY
Action code Failure code Controller code When starting switch is turned OFF and machine monitor does
Trouble
Not set Not set MON not operate normally
• When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
service meter and odometer are not displayed.
Contents of trouble
• When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
• When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
Problem that service meter and odometer are not displayed.
appears on machine • When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
• Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not
Related information
broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring har-
ness.)

When the starting switch is turned
Main power source (SW power
ON, the machine monitor operates
source) is normal.
normally.
Main power source (SW Even if the starting switch is turned
1 Main power source (SW power
power source) defective ON, the machine monitor does not
source) is defective.
operate normally.
aIf the main power source (SW power source) is defective, perform
troubleshooting of MON-1.
Disconnection in wiring har- Wiring harness between J01 (fe- Voltage between BT2
20 – 30 V
ness male) (Y) – fuse BT2 (21) (21) – chassis ground
Possible causes 2
(Disconnection or defective Voltage between
and standard value Wiring harness between fuse BT2
contact) DPC1 (4), (5) – chas- 20 – 30 V
in normal state (22) – DPC1 (female) (4), (5)
sis ground
Hazard lamp switch, related
3 wiring harness, or related re- aReferring to MON-9 d), perform troubleshooting.
lay defective
Machine monitor mode se-
4 lect switch 1 or related wiring aReferring to MON-6, perform troubleshooting.
harness defective
5 Machine monitor defective 3) Insert T-adapter.
aKeep the starting switch OFF.
Between DPC1 (4), (5) – (9), (10) Voltage 20 – 30 V
HD465-7, HD605-7 20-923

(10)
20-924 HD465-7, HD605-7

(1)
MON-3 ALARM BUZZER DEFECTIVE

a) Alarm buzzer does not sound
Action code Failure code Controller code Alarm buzzer defective

Trouble
Not set Not set MON a) Alarm buzzer does not sound
• When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
• If failure code "DV00KB" is displayed, perform troubleshooting for it.
Related information
• Before performing troubleshooting, check that the fuse is not broken and the voltage between BZ2 and
chassis ground is 20 – 30 V when the starting switch is ON.

2) Disconnect connectors BZ2 and battery BT4 terminal (2).
ness
1 Wiring harness between fuse BT4 (2) – BZ2
(female) (1)
contact)
Wiring harness between BZ2 (female) (2) –
Resistance Max. 1 z
DPC (female) (13)
2) Connect BZ2 (2) to the chassis ground.
2 Alarm buzzer defective
Possible causes The alarm buzzer sounds. Alarm buzzer is normal.
and standard value The alarm buzzer does not sound. Alarm buzzer is defective.
in normal state
Under the condition for turning the Voltage between
Max. 1 V
3 Machine monitor defective alarm buzzer ON DPC1 (13) – (9), (10)
20 – 30 V
alarm buzzer OFF DPC1 (13) – (9), (10)
aThe condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
HD465-7, HD605-7 20-925

(10)
b) Alarm buzzer does not stop sounding
Action code Failure code Controller code Alarm buzzer defective

Trouble
Not set Not set MON b) Alarm buzzer does not stop sounding
• When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
Related information
• If failure code "DV00KB" is displayed, perform troubleshooting for it.

2) Disconnect connectors BZ2 and battery BT4 terminal (2).
Short circuit in wiring har- Resistance between wiring harness between fuse BT4 (2)
1
ness – BZ2 (female) (1) and wiring harness between DPC1 (fe- Min. 1 M z
male) (13) – BZ2 (female) (2)
Wiring harness between BZ2 (female) (2) –
Resistance Max. 1 z
DPC (female) (13)
Possible causes
in normal state 2) Disconnect connector DPC1.
Max. 1 V
2 Machine monitor defective alarm buzzer ON DPC1 (13) – (9), (10)
20 – 30 V
alarm buzzer OFF DPC1 (13) – (9), (10)
aThe condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
20-926 HD465-7, HD605-7

(10)
MON-4 ITEMS DISPLAYED BY GAUGES, WARNING LAMPS, AND CHARACTER DIS-

PLAY OF MACHINE MONITOR ARE ABNORMAL
a) Items displayed by gauges are different from machine condition
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character dis-
Trouble play of machine monitor are abnormal
Not set Not set MON a) Items displayed by gauges are different from machine condition
• The items displayed by the gauges, warning lamps, and character display of the machine monitor are
Contents of trouble
abnormal. (The items displayed by the gauges are different from the machine condition.)
Problem that • The items displayed by the gauges, warning lamps, and character display of the machine monitor are
appears on machine abnormal. (The items displayed by the gauges are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Sensor signal system
signal is monitored, the gauges display nor-
is normal.
Sensor signal system defec- mally.
1
tive If the inputting condition of the related sensor
Possible causes Sensor signal system
signal is monitored, the gauges do not display
and standard value is defective.
normally.
in normal state
aIf the sensor signal system is defective, perform troubleshooting for
each related signal system.
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the gauges display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the gauges do not display normally. fective.
HD465-7, HD605-7 20-927

(10)
b) Items displayed by warning lamps are different from machine condition
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character display
of machine monitor are abnormal
Trouble
Not set Not set MON b) Items displayed by warning lamps are different from machine
condition
Contents of trouble
abnormal. (The items displayed by the warning lamps are different from the machine condition.)
appears on machine abnormal. (The items displayed by the warning lamps are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Switch or sensor sig-
signal is monitored, the gauges display nor-
nal system is normal.
mally.
Switch or sensor signal sys- If the inputting condition of the related sensor Switch or sensor sig-
1
tem defective signal is monitored, the gauges do not display nal system is defec-
Possible causes normally. tive.
and standard value
in normal state aIf the switch or sensor signal system is defective, perform trouble-
shooting for each related signal system.
(See troubleshooting for the controllers to which the related sensor
signals are input.)
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the lamps display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the lamps do not display normally. fective.
c) Character display does not display any item or it displays abnormally
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character display
of machine monitor are abnormal
Trouble
Not set Not set MON c) Character display does not display any item or it displays abnor-
mally
Contents of trouble
abnormal. (The character display does not display any item or it displays abnormally.)
appears on machine abnormal. (The character display does not display any item or it displays abnormally.)

Possible causes If the machine monitor check switch is operat- Machine monitor is
and standard value ed, the character display displays normally. normal.
in normal state 1 Machine monitor defective
If the machine monitor check switch is operat-
Machine monitor is de-
ed, the character display does not display nor-
fective.
mally.
20-928 HD465-7, HD605-7

(10)
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY

Trouble Operation of machine monitor cannot be checked normally
Not set Not set MON
• When the machine monitor check switch is operated, any of the lamps and gauges does not display.
Contents of trouble
Or, the lamps continue the operation while the machine monitor check switch is not operated.
Problem that • When the machine monitor check switch is operated, any of the lamps and gauges does not display.
appears on machine Or, the lamps continue the operation while the machine monitor check switch is not operated.

2) Disconnect connector CK1.
3) Check the switch
Machine monitor check
1 Between Operate (Press) the machine mon-
switch defective Resistance Max. 1 z
CK1 itor check switch.
(male) (3) Do not operate (Release) the ma-
– (6) Resistance Min. 1 M z
chine monitor check switch.
2) Disconnect connectors DPC2A, CK1, and fuse BT2 terminal (2).
2 Wiring harness between fuse BT2 (2) – CK1
and standard value (Disconnection or defective Resistance Max. 1 z
(female) (3)
in normal state contact)
Wiring harness between DPC2A (female) (10)
Resistance Max. 1 z
– CK1 (female) (6)
Between Operate (Press) the machine mon-
Voltage 20 – 30 V
DPC2A itor check switch.
(10) –
chassis Do not operate (Release) the ma-
Voltage Max. 1 V
ground chine monitor check switch.
HD465-7, HD605-7 20-929

(10)
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY

a) Machine monitor mode select switch 1 system is abnormal
Action code Failure code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 1 system is abnormal
• Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
Contents of trouble
system is abnormal.)
Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
appears on machine system is abnormal.)

2) Disconnect connector CH1.
Between Press [ ] of the machine monitor
Resistance Max. 1 z
Machine monitor mode se- CH1 select switch 1.
1 lect switch 1 system defec- (male) (2) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select
CH1 switch in NEUTRAL.
(male) (1) Press [ ] of the machine monitor
– (3) Resistance Max. 1 z
select switch 1.
2) Disconnect connectors DPC2A, CH1, and fuse BT2 terminal (22).
Disconnection in wiring har- Wiring harness between fuse BT2 (22) – CH1
2 (female) (3)
Wiring harness between DPC2A (female) (8) –
CH1 (female) (2)
Resistance Max. 1 z
– CH1 (female) (1)
and standard value 2) Disconnect connectors DPC2A and CH1.
Voltage between
Wiring harness between DPC2A DPC2A (female) (8),
Max. 1 V
3 Hot short in wiring harness (female) (8) – CH1 (female) (2) CH1 (female) (2) –
chassis ground
Voltage between
Max. 1 V
(female) (14) – CH1 (female) (1) CH1 (female) (1) –
chassis ground
Between Press [ ] of the machine monitor
Voltage 20 – 30 V
DPC2A select switch 1.
(8) – chas- Set the machine monitor select
sis ground Voltage Max. 1 V
switch in NEUTRAL.
Voltage Max. 1 V
DPC2A switch in NEUTRAL.
(14) –
chassis Press [ ] of the machine monitor
Voltage 20 – 30 V
ground select switch 1.
20-930 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-931

(1)
b) Machine monitor mode select switch 2 system is abnormal
Action code Failure code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 2 system is abnormal
• Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
Contents of trouble
system is abnormal.)
Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
appears on machine system is abnormal.)

2) Disconnect connector CH2.
Between Press [>] of the machine monitor
Resistance Max. 1 z
Machine monitor mode se- CH2 select switch 2.
1 lect switch 2 system defec- (male) (2) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select Resistance Min. 1 M z
CH2 switch in NEUTRAL.
(male) (1) Press [<] of the machine monitor
– (3) Resistance Max. 1 z
select switch 2.
2) Disconnect connectors DPC2A, CH2, and fuse BT2 terminal (2).
Disconnection in wiring har- Wiring harness between fuse BT2 (2) – CH2
2 (female) (3)
CH2 (female) (2)
Resistance Max. 1 z
– CH2 (female) (1)
and standard value 2) Disconnect connectors DPC2A and CH2.
Voltage between
Max. 1 V
3 Hot short in wiring harness (female) (6) – CH2 (female) (2) CH2 (female) (2) –
chassis ground
Voltage between
Max. 1 V
(female) (15) – CH2 (female) (1) CH2 (female) (1) –
chassis ground
Between Press [>] of the machine monitor
Voltage 20 – 30 V
DPC2A select switch 2.
(6) – chas- Set the machine monitor select
sis ground Voltage Max. 1 V
switch in NEUTRAL.
Voltage Max. 1 V
DPC2A switch in NEUTRAL.
(15) –
chassis Press [<] of the machine monitor
Voltage 20 – 30 V
ground select switch 2.
20-932 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-933

(1)
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY

Trouble Power mode select function does not work normally
Not set Not set MON
• When the power mode select switch is operated, the power mode select function does not work nor-
Contents of trouble
mally.
Problem that • When the power mode select switch is operated, the power mode select function does not work nor-
appears on machine mally.

2) Disconnect connector PWM.
Set the power mode select switch
Power mode select switch
1 Between in ECONOMY MODE (Press its Resistance Min. 1 M z
defective
PWM upper part).
(male) (1) Set the power mode select switch
– (3) in HIGH POWER MODE (Press its Resistance Max. 1 z
lower part: Normal work).
2) Disconnect connectors DPC2A, PWM, and fuse BT2 terminal (2).
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) – PWM Resistance Max. 1 z
in normal state (female) (1)
contact)
Resistance Max. 1 z
– PWM (female) (3)
3 Machine monitor defective Set the power mode select switch
Between in ECONOMY MODE (Press its Voltage 20 – 30 V
DPC2A upper part).
(13) –
chassis Set the power mode select switch
ground in HIGH POWER MODE (Press its Voltage Max. 1 V
lower part: Normal work).
20-934 HD465-7, HD605-7

(10)
MON-8 SEAT BELT WARNING LAMP DOES NOT OPERATE NORMALLY

a) Lamp lights up while seat belt is fastened
Action code Failure code Controller code Seat belt warning lamp does not operate normally
Trouble
Not set Not set Not set a) Lamp lights up while seat belt is fastened
Contents of trouble • The lamp lights up while the seat belt is fastened.
Problem that
• The lamp lights up while the seat belt is fastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 z
(1) – (2) Seat belt "Unfastened" Resistance Min. 1 M z
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2).
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) – SBS Resistance Max. 1 z
in normal state (female) (1)
contact)
Wiring harness between DPC2B (female) (11)
Resistance Max. 1 z
– SBS (female) (2)
2) Disconnect connector DPC2B.
3 Machine monitor defective 4) Connect the connector.
Between DPC2B (11) Seat belt "Fastened" Voltage 20 – 30 V
– chassis ground Seat belt "Unfastened" Voltage Max. 1 V
HD465-7, HD605-7 20-935

(10)
b) Lamp does not light up while seat belt is unfastened
Action code Failure code Controller code Seat belt warning lamp does not operate normally
Trouble
Not set Not set MON b) Lamp does not light up while seat belt is unfastened
Contents of trouble • The lamp does not light up while the seat belt is unfastened.
Problem that
• The lamp does not light up while the seat belt is unfastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 z
(1) – (2) Seat belt "Unfastened" Resistance Min. 1 M z
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2).
and standard value 2 ness Voltage between
contact) Wiring harness between DPC2B DPC2B (female) (11),
Max. 1 V
(female) (11) – SBS (female) (2) SBS (female) (2) –
chassis ground
Between DPC2B (11) Seat belt "Fastened" Voltage 20 – 30 V
– chassis ground Seat belt "Unfastened" Voltage Max. 1 V
20-936 HD465-7, HD605-7

(10)
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY

a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Action code Failure code Controller code Turn signals and hazard lamp do not operate normally
Trouble a) When turn signal lever and hazard lamp switch are operated,
Not set Not set Not set any turn signal lamp does not flash
Contents of trouble • When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Problem that
• When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
appears on machine
• Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
• The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp 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.

When hazard relay 2 (R17) is re- No Relay (R17) is normal
3) Check the relay.
Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF.

tive
3) Check the relay.
Possible causes 4) Apply voltage between R17 (male) (1) – (2).
and standard value
Apply 24 V between
tween (1) – (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Disconnection in wiring har- 2) Disconnect connectors R17, FLB, FLL, CM, and R16.
2
(Disconnection or defective Between R17 (female) (3) – FLB Resistance Max. 1 z
contact) Wiring harness between FLL – CM (female) (6)
Resistance Max. 1 z
and branching point of R16 (female) (1), (3)
HD465-7, HD605-7 20-937

(10)
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
light up
Trouble b) When turn signal lever and hazard lamp switch are operated,
Not set Not set MON the turn signal lamps do not flash but light up
• When the turn signal lever and lamp hazard switch are operated, the turn signal lamps do not flash but
Contents of trouble
light up
Problem that • When the turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
appears on machine light up
Related information both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)

2) Disconnect connectors R17, FLB, FLL, CM, and R16.
1 Hot short in wiring harness Resistance between
Wiring harness between FLL, CM
Possible causes FLL, CM (female) (6),
(female) (6), – R16 (female) (1) Max. 1 z
and standard value R16 (female) (1), (3) –
and (3)
in normal state chassis ground
2) Replace the flasher.
2 Flasher defective If the flasher is replaced, the failure is not re-
Flasher is normal
paired.
If the flasher is replaced, the failure is repaired. Flasher is defective
20-938 HD465-7, HD605-7

(10)
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)
c) When turn signal lever is operated, turn signal lamps on either
Trouble
Not set Not set MON or both sides do not flash (When hazard lamp switch is oper-
ated, however, turn signal lamps flash normally)
• When the turn signal lever is operated, the turn signal lamps on either or both sides do not flash (When
Contents of trouble
the hazard lamp switch is operated, however, the turn signal lamps flash normally)
Problem that • When the turn signal lever is operated, however, the turn signal lamps on either or both sides do not
appears on machine flash (When the hazard lamp switch is operated, the turn signal lamps flash normally)

2) Disconnect connector CM.
3) Check the lever.
Set the turn signal le-
Resistance Max. 1 z
Between CM (male) ver in LEFT.
1 Turn signal lever defective (6) – (7) Set the turn signal le-
ver in RIGHT.
Set the turn signal le-
Between CM (male) ver in LEFT.
(6) – (8) Set the turn signal le-
Resistance Max. 1 z
ver in RIGHT.
and standard value Between R17 (male) (1) – (2) Resistance 200 – 400 z
in normal state
tive
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
Disconnection in wiring har- minal (4).
3
(Disconnection or defective Wiring harness between fuse BT1 (4), – R17
Resistance Max. 1 z
contact) (female) (6), – FLB
Wiring harness between CM (female) (6), FLL,
Resistance Max. 1 z
– branching point of R16 (female) (1), (3)
HD465-7, HD605-7 20-939

(10)
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)
d) When hazard lamp switch is turned ON, any turn signal lamp
Trouble
Not set Not set MON does not flash (When turn signal lever is operated, however,
turn signal lamps flash normally)
• When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
Contents of trouble
is operated, however, turn signal lamps flash normally).
Problem that • When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
appears on machine is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 z
HAZ
(male) (1)
Turn the hazard lamp switch OFF. Resistance Min. 1 M z
– (3)
3) Check the relay.

Possible causes 2 2) Disconnect connector R16.
and standard value tive
3) Check the relay.
in normal state 4) Apply voltage between R16 (male) (5) – (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) – (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) – (6).
Hazard relay 2 (R17) defec- placed, is failure repaired?
3 Yes Relay (R17) is defective
tive
3) Check the relay.
20-940 HD465-7, HD605-7

(10)

3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Hazard relay 2 (R17) defec- Between R17 (male) (1) – (2).
3 (5) – (3)
tive Do not apply 24 V be-
tween (1) – (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
Possible causes 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
and standard value minal (4).
Wiring harness between fuse BT1 (24) – R17
Resistance Max. 1 z
(female) (5)
Wiring harness between FLL and R16 (female)
Resistance Max. 1 z
(1) – (3)
(Disconnection or defective chassis ground
contact) Wiring harness between R17 (female) (2) –
Resistance Max. 1 z
chassis ground
Wiring harness between fuse BT2 (24) – HAZ
Resistance Max. 1 z
(female) (1)
Wiring harness between HAZ (female) (3) –
Resistance Max. 1 z
R16 (female) (5)
Wiring harness between HAZ (female) (3) –
Resistance Max. 1 z
R17 (female) (1)
HD465-7, HD605-7 20-941

(10)
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)
e) When hazard lamp switch is turned OFF, turn signal lamps
Trouble
Not set Not set MON continue flashing (When turn signal lever is operated, howev-
er, turn signal lamps flash normally)
• When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
Contents of trouble
lever is operated, however, turn signal lamps flash normally).
Problem that • When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
appears on machine lever is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 z
HAZ
(male) (1)
Turn the hazard lamp switch OFF. Resistance Min. 1 M z
– (3)
3) Check the relay.

tive
in normal state
Apply 24 V between
Resistance Max. 1 z
tween (5) – (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) – (6).
2) Disconnect connectors HAZ, R17, and R16.
Voltage between HAZ
Wiring harness between HAZ (fe- (female) (3), R16 (fe-
ground
Voltage between HAZ
Wiring harness between HAZ (fe- (female) (3), R17 (fe-
Max. 1 V
ground
20-942 HD465-7, HD605-7

(10)
f) Turn signal pilot lamps do not flash normally

(Turn signal lamps flash normally, however)
Trouble f) Turn signal pilot lamps do not flash normally (Turn signal lamps
Not set Not set MON flash normally, however)
Contents of trouble • The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
Problem that
• The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
appears on machine
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
• The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the

2) Disconnect connectors BTC2A and R16.
ness
1 Wiring harness between DPC2A (female) (7) –
R16 (female) (4)
contact)
Resistance Max. 1 z
– R16 (female) (2)
Between Set the turn signal lever in RIGHT. Max. 1 V /
Voltage
DPC2A 20 – 30 V (*)
2 Machine monitor defective (7) – chas- Set the turn signal lever in NEU-
sis ground TRAL. Voltage Max. 1 V
Between Set the turn signal lever in NEU- Voltage Max. 1 V

DPC2A TRAL.
(7) – chas- Max. 1 V /
sis ground Set the turn signal lever in LEFT. Voltage
20 – 30 V (*)
(*) Voltage changes alternately.
HD465-7, HD605-7 20-943

(10)
20-944 HD465-7, HD605-7

(1)
MON-10 NIGHT LIGHTING IS ABNORMAL

a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does
not light up.
Action code Failure code Controller code Night lighting is abnormal

Trouble a) When lamp switch is set in 1st or 2nd position, any of small
Not set Not set Not set lamp, night lamp, and head lamp does not light up.
• When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
Contents of trouble
lamp does not light up.
Problem that • When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
appears on machine lamp does not light up.
• Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12)
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

Between Set the lamp switch in OFF position. Resistance Min. 1 M z

1 Lamp switch defective CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z
(1) – (2) Set the lamp switch in 2nd position. Resistance Max. 1 z
Possible causes
and standard value Between Set the lamp switch in OFF position. Resistance Min. 1 M z
in normal state CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
Disconnection in wiring har- 2) Disconnect connectors CM – fuse BT1 (2)
ness 3) Insert T-adapter.
2
(Disconnection or defective 4) Turn the starting switch ON.
contact) Wiring harness between BT1 (2) – Voltage between CM
20 – 30 V
CM (female) (1) (1) – chassis ground
HD465-7, HD605-7 20-945

(10)
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up

Trouble b) When lamp switch is set in 1st position, small lamp and night
Not set Not set Not set lamp do not light up
Contents of trouble • When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
Problem that
• When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
appears on machine
wiring harness.)
Related information



Possible causes
and standard value
CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
in normal state
2) Disconnect connectors CM and fuse BT1 (2)
ness 4) Turn the starting switch ON.
2
contact) Wiring harness between CM (fe-
Voltage between CM
male) (2), DPC2B (female), – 20 – 30 V
branching point of BT1 (1), (11)
20-946 HD465-7, HD605-7

(10)
c) When lamp switch is OFF, small lamp and night lamp light up

Trouble
Not set Not set MON c) When lamp switch is OFF, small lamp and night lamp light up
Contents of trouble • When the lamp switch is OFF, the small lamp and night lamp light up.
Problem that
• When the lamp switch is OFF, the small lamp and night lamp light up.
appears on machine


Possible causes Between Set the lamp switch in OFF position. Resistance Min. 1 M z
and standard value CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
in normal state (1) – (3) Set the lamp switch in 2nd position. Resistance Max. 1 z
2) Disconnect connectors DPC2B, CM, LS, fuse BT1 (2), and ta-
chograph.
Wiring harness between CM (fe- Voltage between CM
male) (2), DPC2B (female), – (female) (2) – chassis Max. 1 V
branching point of BT1 (1), (11) ground
HD465-7, HD605-7 20-947

(10)
d) When dimmer switch is operated, brightness of night lighting does not change

Trouble d) When dimmer switch is operated, brightness of night lighting
Not set Not set Not set does not change
Contents of trouble • When the dimmer switch is operated, the brightness of the night lighting does not change.
Problem that
• When the dimmer switch is operated, the brightness of the night lighting does not change.
appears on machine
wiring harness.)
Related information

2) Disconnect connectors DPC2B, CM, fuse BT1 (9), (11), Switch, and
Tachograph.
Wiring harness between LS (female) (3) –
1 chassis ground
contact) Wiring harness between LS (female) (2) –
DPC2B (female) (12) (branching point of Resistance Max. 1 z
Possible causes Switch)
and standard value
Wiring harness between LS (female) (1),
in normal state
DPC2B (female) (5) – branching point of BT1 Resistance Max. 1 z
(9), (11) Tachograph
2 Dimmer switch defective 5) Turn the starting switch ON.
6) Set the lamp switch in 1st position.
Between LS (1) – (3) Voltage 20 – 30 V
Between LS (2) – (3) Voltage 6 – 27 V
20-948 HD465-7, HD605-7

(10)
e) Head lamp "Hi" beam does not light up

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
wiring harness.)
Related information



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) (1) – (2) Resistance 200 – 400 z
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) – (2).
2) Disconnect connectors DPC2B, CM, fuse BT1 (9) – (11), Switch,
and Tachograph
ness
3
(Disconnection or defective Wiring harness between R30 (female) (1), (3) Resistance Max. 1 z
contact) – branching point of wiring harness
Resistance Max. 1 z
DCP1 (female) (14)
Resistance Max. 1 z
branching point of wiring harness
HD465-7, HD605-7 20-949

(10)
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



Possible causes
2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1
and standard value
terminals (5) and (6)
in normal state
Wiring harness between PL1 (female) (1) –
Resistance Max. 1 z
chassis ground
Disconnection in wiring har- Wiring harness between PR1 (female) (1) –
2 chassis ground
contact) Wiring harness between battery relay terminal
M (CN-02), fuse BT1 terminals (1), (2), – CM Resistance Max. 1 z
(female) (1)
Wiring harness between CM (female) (3) –
Resistance Max. 1 z
fuse BT1 terminal (7)
Wiring harness fuse BT1 terminal (8) – PL1
Resistance Max. 1 z
(female) (1), PR1 (female) (1)
20-950 HD465-7, HD605-7

(10)
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 z
CM (male)
Set the passing switch in RETURN
(4) – (5) Resistance Min. 1 M z
(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
3) Check the relay.
Possible causes 4) Apply voltage between R29 (male) (1) – (2).
tween (1) – (2).
2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1
terminals (5) and (6)
Wiring harness between PL2 (female) (1) –
Resistance Max. 1 z
chassis ground
Wiring harness between PR2 (female) (1) –
Resistance Max. 1 z
chassis ground
ness Wiring harness between fuse BT1 terminal (6)
(Disconnection or defective – PL2 (female) (1), PR2 (female) (1)
contact) Wiring harness between R29 (female) (2) –
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
Resistance Max. 1 z
R29 (female) (1)
Resistance Max. 1 z
HD465-7, HD605-7 20-951

(10)
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.
1
CM (female) (5) – R29 (female) (1)
and standard value 2) Disconnect connector DPC2A.
Set the passing switch
Voltage Max. 1 V
Between DPC2A (5) – in "Lo".
chassis ground Set the passing switch
Voltage 20 – 30 V
in "Hi".
20-952 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-953

(2)
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY

a) Operating left side does not
Action code Failure 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 (8) are not broken. (If any of them is broken,
Related information
there is a ground fault. Accordingly, check the related wiring harness.)

Power window switch (L.H.) "Left
Between up" Resistance Min. 1 M z
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M z
Power window switch (L.H.) (male) (1)
1 – (2) Power window switch (L.H.) "Left
defective Resistance Max. 1 z
down"
Power window switch (L.H.) "Left
Between up" Resistance Max. 1 z
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M z
(male) (1)
– (3) 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 (8).
and standard value 4) Connect the connectors.
Wiring harness between fuse BT2 terminal (8)
Resistance Max. 1 z
– R34 (female) (1)
Wiring harness between fuse BT2 terminal (8)
Resistance Max. 1 z
Disconnection in wiring har- – R25 (female) (8)
contact)
Resistance Max. 1 z
CAB1 (5) – PWL (female) (1)
Resistance Max. 1 z
CAB1 (6) – PWL (male) (1)
Resistance Max. 1 z
R34 (female) (2)
Resistance Max. 1 z
chassis ground
2) Replace power window motor (L.H.) with motor normal one.
Power window motor (L.H.) aIf 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

(10)
b) Operating right side does not
Action code Failure 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 (10) are not broken. (If any of them is broken,
Related information
there is a ground fault. Accordingly, check the related wiring harness.)

Power window switch (R.H.) "Right
Between up" Resistance Min. 1 M z
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M z
Power window switch (R.H.) (male) (1)
1 – (2) Power window switch (R.H.) "Right
defective Resistance Max. 1 z
down"
Power window switch (R.H.) "Right
Between up" Resistance Max. 1 z
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M z
(male) (1)
– (3) 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 (10).
and standard value 4) Connect the connectors.
Resistance Max. 1 z
(10) – R35 (female) (1)
Resistance Max. 1 z
Disconnection in wiring har- (10) – R25 (female) (11)
contact)
Resistance Max. 1 z
CAB1 (7) – PWR (female) (1)
Resistance Max. 1 z
CAB1 (8) – PWR (male) (1)
Resistance Max. 1 z
R35 (female) (2)
Resistance Max. 1 z
chassis ground
2) Replace power window motor (R.H.) with motor normal one.
Power window motor (R.H.) a 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

(10)
20-956 HD465-7, HD605-7

(2)
MON-12 DEFECTIVE AIR CONDITIONER

a) Air conditioner does not operate
Action code Failure code Controller code Defective air conditioner

Trouble
Not set Not set Not set 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
ground fault.

2) Disconnect connector ACP1 and fuse BT3 (4) terminal.
1 Wiring harness between fuse BT3 (4) – ACP1
and standard value (Disconnection or defective Resistance Max. 1 z
(female) (1)
in normal state contact)
Wiring harness between ACP1 (female) (14) –
Resistance Max. 1 z
chassis ground
Defective air conditioner
2 a Check the control panel and repair or replace it, if it has abnormality.
control panel
HD465-7, HD605-7 20-957

(10)
b) Air does not come out or air flow cannot be adjusted

Trouble
Not set Not set Not set 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) – ACR1
Resistance Max. 1 z
(female) (1)
Disconnection in power
supply wiring harness Wiring harness between fuse BT3 (4) – ACR2
(Disconnection or defective (female) (1)
contact) Wiring harness between fuse BT3 (4) – ACR3
Resistance Max. 3 z
(female) (1)
Resistance Max. 4 z
(female) (1)
Resistance Max. 1 z
(female) (3)
2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Resistance Max. 1 z
ACR1 (female) (2)
Possible causes
and standard value Wiring harness between ACP1 (female) (5) –
Resistance Max. 1 z
in normal state ACR2 (female) (2)
Resistance Max. 1 z
ACR3 (female) (2)
Resistance Max. 1 z
ACR4 (female) (2)
Wiring harness between ACR1 (female) (4) –
Disconnection in wiring Resistance Max. 1 z
harness ACBM (female) (1)
2
(Disconnection or defective Wiring harness between ACR2 (female) (3) –
Resistance Max. 1 z
contact) ACBM (female) (2), ACRE (female) (1)
Resistance Max. 1 z
ACRE (female) (2)
Resistance Max. 1 z
ACRE (female) (3)
wiring harness between ACR2 (female) (4) –
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
chassis ground
wiring harness between ACRE (female) (4) –
Resistance Max. 1 z
chassis ground
20-958 HD465-7, HD605-7

(10)

2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Wiring harness between Resistance between ACR1
ACR1 (female) (4) – ACBM (female) (4), ACBM (female) Min. 1 M z
3 ACR2 (female) (3) – ACBM (female) (3), ACBM (female)
ness Min. 1 M z
(female) (2), ACRE (female) (2), ACRE (female) (1) –
(1) chassis ground
ACR3 (female) (3) – ACRE (female) (3), ACRE (female) Min. 1 M z
ACR4 (female) (3) – ACRE (female) (3), ACRE (female) Min. 1 M z
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) – (2) Resistance 2.8 z
Between ACRE (female) (1) – (3) Resistance 4.8 z
Between ACRE (female) (1) – (4) Resistance 4.0 z
control panel
HD465-7, HD605-7 20-959

(10)
c) Air is not cooled or temperature cannot be adjusted (Electric system)

Trouble c) Air is not cooled or temperature cannot be adjusted (Electric
Not set Not set Not set system)
Contents of trouble • Air is not cooled or temperature cannot be adjusted
Problem that
• Air is not cooled or temperature cannot be adjusted
appears on machine
• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information ground 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) – ACR5
(female) (1)
contact)
Resistance Max. 1 z
(female) (3)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Resistance Max. 1 z
ACPS (female) (2)
Resistance Max. 1 z
ACTH (female) (1)
Resistance Max. 1 z
ACM1(female) (4)
Disconnection in wiring har- ACTH (female) (2) Resistance Max. 1 z
2 ness (Disconnection or de-
fective contact) Resistance Max. 1 z
Possible causes ACM1 (female) (3)
and standard value Wiring harness between ACP1 (female) (16) –
ACM1 (female) (1)
Resistance Max. 1 z
ACM1 (female) (2)
Resistance Max. 1 z
ACM1 (female) (5)
Resistance Max. 1 z
ACPS (female) (1)
Resistance Max. 1 z
E07 (female) (1)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Wiring harness between Resistance between ACP1
ACP1 (female) (6) – ACPS (female) (6), ACPS (female) Min. 1 M z
3
ness
ACP1 (female) (9) – ACTH (female) (9), ACTH (female) Min. 1 M z
ACP1 (female) (10) – ACM1 (female) (10), ACM1 (female) Min. 1 M z
20-960 HD465-7, HD605-7

(10)

ACP1 (female) (13) – ACTH (female) (13), ACTH (female) Min. 1 M z
ACP1 (female) (13) – ACM1 (female) (13), ACM1(female) Min. 1 M z
3
ness
ACR5 (female) (2) – ACPS (female) (2), ACPS (female) Min. 1 M z
ACR5 (female) (4) – E07 (fe- (female) (4), E07 (female) Min. 1 M z
male) (1) (1) – 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
Air conditioner switch OFF Resistance Min. 1 M z
Between ACPS
(male) (1) – (2) Air conditioner switch ON in Resistance Max. 1 z
cooling mode
2) Disconnect connector ACTH.
6 Defective thermistor 4) Start air conditioner.
Between ACTH (male) Temperature: 25°C Resistance 37 – 50 k z
(1) – (2) Temperature: 100°C Resistance 3.5 – 4.0 k z
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

(10)

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.
control panel
d) Recirculated air and fresh air cannot be selected

Trouble
Not set Not set Not set 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) –
ACM3 (female) (2)
contact)
Resistance Max. 1 z
ACM3 (female) (5)
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors ACP2 and ACM3.
2 ACP2 (female) (5) – ACM3 (female) (5), ACM3 (female) Min. 1 M z
ness
control panel
20-962 HD465-7, HD605-7

(10)
e) Air outlets cannot be selected

Trouble
Not set Not set Not set 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.
Resistance Max. 1 z
ACM2 (female) (4)
Disconnection in wiring Wiring harness between ACP1 (female) (13) –
harness Resistance Max. 1 z
1 ACM2 (female) (3)
ACM2 (female) (2)
Resistance Max. 1 z
ACM2 (female) (5)
Resistance Max. 1 z
ACM2 (female) (1)
2) Disconnect connectors ACP1, ACP2, and ACM2.
and standard value
in normal state
2
ness Wiring harness between Resistance between ACP2
control panel
HD465-7, HD605-7 20-963

(10)
20-964 HD465-7, HD605-7

(5)
f) Air is not cooled (Mechanical system)

Trouble
Not set Not set Not set 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.
• Check and repair or replace, if abnormal.
4 Defective expansion valve a Check the valve for excessive opening and defective contact of
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

(10)
g) Air is not heated (Defective hot water circuit)

Trouble
Not set Not set Not set 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.

• Check heater core fins for clogging and clean them, if necessary.
1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet
of the heater core becomes high.
• Check and repair or replace leaking part.
Air leakage through air con-
2 a If this is the cause, the temperature at the hot water inlet and outlet
ditioner unit
of the heater core becomes high.
Possible causes • Check and remove clogging material, or replace valve.
and standard value 3 Defective water valve a If this is the cause, the temperature at the hot water inlet of the heat-
in normal state (Clogging or defective valve)
er core becomes high but that at the hot water outlet becomes low.
a If this is the cause, the temperature at the hot water inlet of the heat-
4 Clogging of heater core
er core becomes high but that at the hot water outlet becomes low.

Clogging up to hot water
5 a If this is the cause, the temperature at the hot water inlet of the heat-
inlet of heater core
er core becomes low.
h) Abnormal sound comes out

Trouble
Not set Not set Not set 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

(10)
i) Water leaks

Trouble
Not set Not set Not set 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

(10)
TROUBLESHOOTING OF VHMS CONTROLLER
SYSTEM (VHMS MODE)
Electricahot short in wiring harnessl system diagram related VHMS controller ........................................ 20-1002
Information given in troubleshooting chart ................................................................................................ 20-1004
Phenomenon 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 (Hot short)
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 (Hot short)
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 (Hot short)
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 (Hot short)
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

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
20-1002 HD465-7, HD605-7

(5)
HD465-7, HD605-7 20-1003

(5)
20-1003-1 HD465-7, HD605-7

(5)
TROUBLESHOOTING INFORMATION GIVEN IN TROUBLESHOOTING CHART
INFORMATION GIVEN IN TROUBLESHOOTING CHART

a 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 • Ground fault
Wiring harness not connected to GND (ground) circuit is in contact
with GND circuit.
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>
1) 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).
2) 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

(10)
TROUBLESHOOTING PHENOMENON 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.
PHENOMENON TYPE CODE LIST

a For phenomenon type codes marked "See list", refer to this list.
code code
KA Disconnection L0 Fill signal for non-existent combination of clutches ON simulta-

neously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
KK Drop in power source volt- L2 Fuel pressure is higher than max. specified value.
age, input
KQ Mismatch in model selec- L3 Target components cannot be controlled.

tion signal
KR Defective communications L4 ON/OFF signals from 2 systems do not match.
Abnormality inside con- Engine speed signal, C terminal signal, oil pressure switch,
KT troller L6 coolant temperature sensor signals do not match operating
condition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
KY Short circuit with power LC Speed signals of 2 systems do not match.

source (Hot short)
KZ Disconnection or short cir- LD Switch remains pressed for length of time unthinkable for nor-
cuit mal operations .
MA Defective function LH Fill signal is turned OFF when command current to ECMV is
ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
HD465-7, HD605-7 20-1005

(10)
TROUBLESHOOTING [A000N1]
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN

Trouble Engine overrun
Not set A000N1 Not set
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 idle speed Power mode 2,270 ± 50 rpm
01001
20-1006 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DBB0KK]
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE

VOLTAGE

Trouble Abnormality source voltage
Not set DBB0KK Not set
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) – battery relay CN-02 (Terminal M) Resistance Max. 1 z
fective contact)
Wiring harness between HM-CN1 (female)
Resistance Max. 1 z
(11), (12) – ER
Wiring harness between HM-CN1 (female)
Probable cause Resistance Max. 1 z
(19), (20) – 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-
ness
HM-CN1 (female) (8), (9) – CN1 (female) (8), (9) – chas-
battery relay CN-02 (Termi- sis ground Min. 1 M z
nal M) and wiring harnesses
related to it
2) Disconnect HM-CN1.
4 Defective VHMS controller 3) Connect T-adapter.
Between HM-CN1 (8), (9) – chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-1

(10)
TROUBLESHOOTING [DBB0KK]
20-1006-2 HD465-7, HD605-7

(5)
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
Not set DBB5KP Not set
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.
1 Wiring harness between Resistance between HM-
ness
HM-CN1 (female) (4), (5) – CN1 (female) (4), (5), HM-
Min. 1 M z
HM-12 (female) (B) CN12 (female) (B) – chassis
ground
Probable cause
2) Disconnect connectors HM-CN1 and HM-12.
and standard value
when normal
Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (4), (5) – (female) (4), (5), HM-12 (fe- Max. 1 V
HM-12 (female) (B) male) (B) – chassis ground
2) Disconnect connector HM-CN1.
Between HM-CN1 (4), (5) – (11), (12) Voltage 4.5 – 5.5 V
HD465-7, HD605-7 20-1006-3

(10)
20-1006-4 HD465-7, HD605-7

(5)

SOURCE (24 V) SYSTEM

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) – HM- CN1 (female) (2), HM-23A
Min. 1 M z
23A (female) (A), HM-23B (female) (A), HM-23B (fe-
Ground fault in wiring har- (female) (A) male) – chassis ground
1
ness Wiring harness between Resistance between HM-
HM-CN1 (female) (2) – HM- CN1 (female) (2), HM-SUFL
Min. 1 M z
SUFL (female) (B), HM- (female) (B), HM-SUFR (fe-
SUFR (female) (B) male) (B) – chassis ground
Wiring harness between HM- Resistance between HM-
CN1 (female) (2) – HM- CN1 (female) (2), HM-SURL
Min. 1 M z
SURL (female) (B), HM- (female) (B), HM-SURR (fe-
SURR (female) (B) male) (B) – 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.
HM-CN1 (female) (2) – HM- (female) (2), HM-23A (fe-
Max. 1 V
23A (female) (A), HM-23B male) (A), HM-23B (female)
2 Hot short in wiring harness (female) (A) (A) – chassis ground
HM-CN1 (female) (2) – HM- (female) (2), HM-SUFL (fe-
Max. 1 V
SUFL (female) (B), HM- male) (B), HM-SUFR (fe-
SUFR (female) (B) male) (B) – chassis ground
HM-CN1 (female) (2) – HM- (female) (2), HM-SURL (fe-
Max. 1 V
SURL (female) (B), HM- male) (B), HM-SURR (fe-
SURR (female) (B) male) (B) – chassis ground
2) Disconnect connector HM-CN1.
Between HM-CN1 (2) – (11), (12) Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-5

(10)
20-1006-6 HD465-7, HD605-7

(5)

SOURCE (12 V) SYSTEM

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
ness Wiring harness between Resistance between HM-
HM-CN1 (female) (3) – GDL CN1 (female) (3), GDL Min. 1 M z
(male) (1) (male) (1) – chassis ground
Probable cause 2) Disconnect connectors HM-CN1 and GDL.
when normal 2 Hot short in wiring harness 4) Turn starting switch ON.
HM-CN1 (female) (3) – GDL (female) (3), GDL (male) (1) Max. 1 V
(male) (1) and chassis ground
2) Disconnect HM-CN1.
3 Defective VHMS controller 3) Insert T-adapter.
Between HM-CN1 (3) – (11), (12) Voltage 10 – 15V
HD465-7, HD605-7 20-1006-7

(10)
20-1006-8 HD465-7, HD605-7

(5)
TROUBLESHOOTING [DBBRKR]
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS:

DEFECTIVE COMMUNICATIONS (KR)
(BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)
Action code Failure code Controller code Defective CAN communications: Defective communications (KR)
Trouble
E03 DBBRKR Not set (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 z
(4) – CAN1 (female) (A)
contact)
Wiring harness between HM-CN4A (female)
Resistance Max. 1 z
(12) – CAN1 (female) (B)
2) Disconnect connectors HM-CN4A and CAN1.
Resistance between HM-
Wiring harness between
CN4A (female) (4), CAN1
Ground fault in wiring har- HM-CN4A (female) (4) – Max. 1 z
2 (female) (A) – chassis
ness CAN1 (female) (A)
ground
CN4A (female) (12), CAN1
Probable cause HM-CN4A (female) (12) – Max. 1 z
(female) (B) – chassis
and standard value CAN1 (female) (B)
ground
when normal
2) Disconnect connector HM-CN4A.
Wiring harness between Voltage between HM-CN4A
HM-CN4A (female) (4) – (female) (4), CAN1 (female) Max. 1 V
CAN1 (female) (A) (A) – chassis ground
HM-CN4A (female) (12) – (female) (12), CAN1 (fe- Max. 1 V
CAN1 (female) (B) male) (B) – 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

(10)
TROUBLESHOOTING [DBBRKR]
20-1008 HD465-7, HD605-7

(2)
TROUBLESHOOTING [DBBSKR]
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS:

(KR)

Trouble Defective S-NET communications: (KR)
E03 DBBSKR Not set
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 (8) – JCB (female) (8)
(disconnection, defective
(18) – JCD (female) (4)
Resistance Max. 1 z
(9) ,(17) – JCC (female) (4), JCE (female) (4)
2) Disconnect connectors HM-CN3A, JCB, and JCD.
Ground fault in wiring har- HM-CN3A (female) (8) – CN3A (female) (8), JCB (fe- Min. 1 Mz
2
ness JCB (female) (8) male) (8) – chassis ground
Probable cause Resistance between HM-

and standard value CN3A (female) (18), JCD
HM-CN3A (female) (18) – Min. 1 Mz
when normal (female) (4) – chassis
JCD (female) (4)
ground
2) Disconnect connector HM-CN3A, JCB, and JCD.
3 Hot short in wiring harness HM-CN3A (female) (8) – (female) (18), JCB (female) Max. 1 V
JCB (female) (8) (8) – chassis ground
HM-CN3A (female) (18) – (female) (18), JCD (female) Max. 1 V
JCD (female) (4) (4) – chassis ground
4 Defective VHMS controller 4) Connect connector.
Between HM-CN3A (8) – (17) Voltage Max. 6 – 9 V
Between HM-CN3A (18) – (17) Voltage Max. 6 – 9 V
HD465-7, HD605-7 20-1009

(10)
TROUBLESHOOTING [DBBSKR]
20-1010 HD465-7, HD605-7

(2)
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 Failure code Controller code Disconnection, short circuit with chassis ground in engine oil
Trouble temperature sensor system (KB)
Not set DGE1KB Not set {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.
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) (1) – 25 °C Resistance Approx. 35 – 50 kz
(2) 100 °C Resistance Approx. 3.3 – 4.3 kz
2) Disconnect connectors HM-CN2A and HM-31.
harness
Probable cause (3) – HM-31 (female) (1)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 z
(12) – HM-31 (female) (2)
2) Disconnect connector HM-CN2A and HM-31.
3 Resistance between HM-
ness Wiring harness between
CN2A (female) (3), HM-31
HM-31 (female) (1)
ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kz
(3) – (12) 100 °C Resistance Approx. 3.3 – 4.3 kz
HD465-7, HD605-7 20-1011

(10)
TROUBLESHOOTING [DGE1KY]
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER

SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM
(KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine oil temper-
Trouble
Not set DGE1KY Not set ature sensor 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 ON.
Between HM-31 (male) (1) – 25 °C Resistance Approx. 35 – 50 kz
(2) 100 °C Resistance Approx. 3.3 – 4.3 kz
Probable cause 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors HM-CN2A and HM-31.
when normal 3) Connect T-adapter.
HM-CN2A (female) (3) – (female) (3), HM-31 (female) Max. 1 V
HM-31 (female) (1) (1) – chassis ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kz
(3) – (12) 100 °C Resistance Approx. 3.3 – 4.3 kz
20-1012 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DGE5KX]
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE

SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)
Action code Failure code Controller code Failure in ambient temperature sensor system: Input signal out-
Trouble
Not set DGE5KX Not set 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

Defective ambient
temperature sensor
0 °C Resistance Approx. 10 – 15 kz
Between HM-35 (male) (1) –
(2)
harness
Probable cause (10) – HM-35 (female) (1)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 z
(12) – HM-35 (female) (2)
3 Resistance between HM-
ness Wiring harness between
HM-35 (female) (1)
ground
4 Defective VHMS controller 0 °C Resistance Approx. 10 – 15 kz
Between HM-CN2A (female)
(10) – (12)
HD465-7, HD605-7 20-1013

(10)
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 Failure code Controller code Disconnection, short circuit with chassis ground in No. 1, 2, 3
Trouble
Not set DGT4KA Not set (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 (A) – (C) Voltage 20 – 30 V
HM-23A Between (B) – 20 °C Voltage Approx. 0.9 – 1.2 V
(C) 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
Wiring harness between HM-CN1 (female) (2)
when normal Disconnection in wiring Resistance Max. 1 z
harness – HM-23A (female) (A)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
(7) – HM-23A (female) (B)
Wiring harness between HM-22A (female) (1)
Resistance Max. 1 z
– HM-21A (female) (1)
Wiring harness between HM-22A (female) (2)
Resistance Max. 1 z
– HM-21A (female) (2)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Ground fault in wiring har- CN1 (female) (2), HM-23A
4 HM-CN1 (female) (2) – HM- Min. 1 Mz
ness (female) (A) – chassis
23A (female) (A)
ground
CN2A (female) (7), HM-23A
HM-23A (female) (B)
ground
20-1014 HD465-7, HD605-7

(10)

2) Disconnect connectors HM-CN1 and HM-CN2A.
Probable cause 3) Insert T-adapter.
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
Between HM-CN1 (2) – HM-CN2A (12) Voltage 20 – 30 V
Between HM-CN2A (7) – 20 °C Voltage Approx. 0.9 – 1.2V
(12) 500 °C Voltage Approx. 2.6 – 3.5 V
HD465-7, HD605-7 20-1015

(10)
TROUBLESHOOTING [DGT4KB]
[DGT4KB] (OR VHMS_LED DISPLAYS [n311])

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3
(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 1, 2, 3 (front)
Trouble
Not set DGT4KB Not set exhaust temperature 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 (B) – 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21A and HM-22A.
Probable cause Ground fault in wiring har-
and standard value 3 ness Resistance between HM-
when normal 22A (female) (1),
HM-22A (female) (1) – HM- Min. 1 Mz
HM-21A (female) (1) – chas-
21A (female) (1)
sis ground
2) Disconnect connectors HM-CN2A and HM-23A.
CN2 (female) (7),
HM-23A (female) (B) – chas-
HM-23A (female) (B)
sis ground
5 Defective VHMS controller 5) Start engine.
Between HM-CN2A (7) – 20 °C Voltage Approx. 0.9 – 1.2 V
20-1016 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1017

(2)
[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 Failure code Controller code Disconnection, short circuit with chassis ground in No. 4, 5, 6
Trouble
Not set DGT5KA Not set (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 (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 (B) – 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
Wiring harness between HM-CN1 (female) (2)
when normal Disconnection in wiring Resistance Max. 1 z
harness – HM-23B (female) (A)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
(5) – HM-23B (female) (B)
Wiring harness between HM-22B (female) (1)
Resistance Max. 1 z
– HM-21B (female) (1)
Wiring harness between HM-22B (female) (2)
Resistance Max. 1 z
– HM-21B (female) (2)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Ground fault in wiring har- CN1 (female) (2), HM-23B
4 HM-CN1 (female) (2) – Min. 1 Mz
ness (female) (A) – chassis
HM-23B (female) (A)
ground
CN2A (female) (5), HM-23B
HM-23B (female) (B)
ground
20-1018 HD465-7, HD605-7

(10)

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

(10)
[DGT5KB] (OR VHMS_LED DISPLAYS [n321])

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6
(REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 4, 5, 6 (rear) ex-
Trouble
Not set DGT5KB Not set haust temperature 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 (B) – 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21B and HM-22B.
Probable cause Ground fault in wiring har-
and standard value 3 ness Resistance between
when normal HM-22B (female) (1),
HM-22B (female) (1) – HM- Min. 1 Mz
HM-21B (female) (1) –
21B (female) (1)
chassis ground
2) Disconnect connectors HM-CN2A and HM-23B.
Resistance between
HM-CN2 (female) (5),
HM-23B (female) (B) –
HM-23B (female) (B)
chassis ground
20-1020 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1021

(2)
TROUBLESHOOTING [DHE5KB]
[DHE5KB] (OR VHMS_LED DISPLAYS [n332])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE
BLOW-BY PRESSURE SENSOR SYSTEM (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine blow-
Trouble
Not set DHE5KB Not set 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 (B) – (A) Voltage 4.5 – 5.5V
Between HM-12 (C) – (A) 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)
Resistance Max. 1 z
tive contact) (4),(5) – HM-12 (female) (B)
Resistance Max. 1 z
(18) – HM-12 (female) (C)
Probable cause
and standard value 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
when normal
CN1 (female) (4),(5), HM-12
Ground fault in wiring har- HM-CN1 (female) (4),(5) – Min. 1 Mz
3 (female) (B) – chassis
ness HM-12 (female) (B)
ground
(female) (C) - chassis
HM-12 (female) (C)
ground
4 Defective VHMS controller
5) Start engine.
Between HM-CN1 (5) – HM-CN2A (12) Voltage 4.5 – 5.5V
Between HM-CN2A (18) – (12) Voltage 0.3 – 0.7V
20-1022 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DHE5KY]
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER

SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYS-
TEM (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine blow-by
Trouble
Not set DHE5KY Not set pressure sensor 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 (B) – (A) Voltage 4.5 – 5.5 V
Between HM-12 (C) – (A) Voltage 0.3 – 0.7 V
Probable cause
and standard value
when normal
HM-CN2A (female) (18) – (female)(18), HM-12 (fe- Max. 1 V
HM-12 (female) (C) male) (C) – chassis ground
Between HM-CN1 (5) – HM–CN2A (12) Voltage 4.5 – 5.5 V
Between HM-CN2A (18) – (12) Voltage 0.3 – 0.7 V
HD465-7, HD605-7 20-1023

(10)
TROUBLESHOOTING [DhP4KX]
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure 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) – SUFR (female) (C)
fective contact) Wiring harness between HM-CN1 (female) (2)
Resistance Max. 1 z
– SUFR (female) (B)
Wiring harness between HM-CN2B (female)
Resistance Max. 1 z
(9) – SUFR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
CN2B (female) (1), SUFR
Ground fault in wiring har- HM-CN2B (female) (1) – Min. 1 M z
2 (female) (C) – chassis
ness SUFR (female) (C)
ground
CN1 (female) (2), SUFR
HM-CN1 (female) (2) – Min. 1 M z
Probable cause SUFR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SUFR.
Wiring harness between Voltage between HM-CN2B
HM-CN2B (female) (1) – (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) – (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) – HM-CN2B (9) Voltage 20 – 30 V
Between HM-CN2B (1) – (9) Voltage 1.0 – 4.6 V
20-1023-1 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-2

(5)
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure 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:

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
1 ness (Disconnection or de- (2) – SUFL (female) (C)
Resistance Max. 1 z
– SUFL (female) (B)
Resistance Max. 1 z
(9) – SUFL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
Ground fault in wiring har- CN2B (female) (2), SUFL
2 HM-CN2B (female) (2) – Min. 1 M z
ness (female) (C) – chassis
SUFL (female) (C)
ground
HM-CN1 (female) (2) – CN1 (female) (2), SUFL (fe- Min. 1 M z
Probable cause SUFL (female) (B) male) (B) – chassis ground
when normal 2) Disconnect connectors HM-CN2B and SUFL.
HM-CN2B (female) (2) – (female) (2), SUFL (female) Max. 1 V
4
sure sensor (Front left) 5) Turn starting switch ON.
Between SUFL (B) – (A) Voltage 20 – 30 V
5
20-1023-3 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-4

(5)
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure 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.
1 ness (Disconnection or de- (7) – SURR (female) (C)
Resistance Max. 1 z
– SURR (female) (B)
Resistance Max. 1 z
(9) – SURR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
CN2B (female) (7), SURR
Ground fault in wiring har- HM-CN2B (female) (7) – Min. 1 M z
2 (female) (C) – chassis
ness SURR (female) (C)
ground
CN1 (female) (7), SURR
HM-CN1 (female) (2) – Min. 1 M z
Probable cause SURR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SURR.
HM-CN2B (female) (7) – (female) (7), SURR (female) Max. 1 V
SURR (female) (C) (C) – chassis ground
2) Disconnect connector SURR.
4
sure sensor (Rear right) 5) Turn starting switch ON.
Between SURR (B) – (A) Voltage 20 – 30 V
Between SURR (C) – (A) Voltage 1.0 – 4.6 V
5
20-1023-5 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-6

(5)
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure 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.
1 ness (Disconnection or de- (8) – SURL (female) (C)
Resistance Max. 1 z
– SURL (female) (B)
Resistance Max. 1 z
(9) – SURL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
Ground fault in wiring har- CN2B (female) (8), SURL
2 HM-CN2B (female) (8) – Min. 1 M z
ness (female) (C) – chassis
SURL (female) (C)
ground
HM-CN1 (female) (2) – CN1 (female) (2), SURL (fe- Min. 1 M z
Probable cause SURL (female) (B) male) (B) – chassis ground
when normal 2) Disconnect connectors HM-CN2B and SURL.
HM-CN2B (female) (8) – (female) (8), SURL (female) Max. 1 V
SURL (female) (C) (C) – chassis ground
2) Disconnect connector SURL.
4
sure sensor (Rear left) 5) Turn starting switch ON.
Between SURL (B) – (A) Voltage 20 – 30 V
Between SURL (C) – (A) Voltage 1.0 – 4.6 V
5
20-1023-7 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-8

(5)
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:

2) Disconnect connectors HM-CN1, HM-CN2B, and PM3.
1 ness (Disconnection or de- (3) – PM3 (female) (B)
Resistance Max. 1 z
– PM3 (female) (C)
Resistance Max. 1 z
(9) – PM3 (female) (A)
2) Disconnect connectors BRC3B and PM3.
2 HM-CN2B (female) (3) – CN2B (female) (3), PM3 (fe- Min. 1 M z
ness
PM3 (female) (B) male) (B) – chassis ground
HM-CN1 (female) (2) – CN1 (female) (2), PM3 (fe- Min. 1 M z
PM3 (female) (C) male) (C) – chassis ground
Probable cause
when normal 2) Disconnect connectors BRC3B and PM3.
HM-CN2B (female) (3) – (female) (3), MP3 (female) Max. 1 V
PM3 (female) (B) (B) – chassis ground
2) Disconnect connectors PM3.
4 Defective pitch angle sensor 4) Connect connector.
Between PM3 (C) – (A) Voltage 20 – 30 V
Between PM3 (B) – (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors HM-CN1 and HM-CN2B
5
20-1023-9 HD465-7, HD605-7

(10)
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)
Not set F@BBZL Not set
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

(10)
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)
Not set F@BYNR Not set
• 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

(10)
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)
Not set F@BYNS Not set
• 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

(10)
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)
Not set F@BZNR Not set
• 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

(10)
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)
Not set F@BZNS Not set
• 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 (5) – 20° C Voltage Approx. 0.9 – 1.2 V
20-1028 HD465-7, HD605-7

(10)
TROUBLESHOOTING VHMS-1
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION

a) Satellite communication data are not transmitted
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set 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

Machine is in tunnel or build- • Not defective.
1
ing aMove the machine outdoors.
Machine is behind building • Not defective.
2 or mountain and only a part aMove the machine to a place from where you can look out over the
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) –
Resistance Max. 1 z
HM-CN4B (female) (4)
Wiring harness between ORB-B (female) (2) –
Probable cause Disconnection in wiring har- HM-CN4B (female) (10) Resistance Max. 1 z
and standard value 6 ness (Disconnection or de-
when normal Wiring harness between ORB-B (female) (3) –
fective contact) Resistance Max. 1 z
HM-CN4B (female) (3)
Wiring harness between ORB-A (female) (7),
Resistance Max. 1 z
(8) – HM-CN1 (female) (6), (7)
Wiring harness between ORB-A (female) (10),
Resistance Max. 1 z
(11) – HM-CN1 (female) (19), (20)
Wiring harness between ORB-A (female) (2) –
Resistance Max. 1 z
HM-CN2 (female) (17)
and ORB-B.
Wiring harness between Resistance between ORB-B
ORB-B (female) (1) – HM- (female) (1), HM-CN4B (fe- Min. 1M z
Ground fault or short circuit CN4B (female) (4) male) (4) – chassis ground
7
in wiring harness
CN4B (female) (10) male) (10) – chassis ground
HD465-7, HD605-7 20-1029

(10)

Resistance between ORB-A
(female) (7), (8), HM-CN1
ORB-A (female) (7), (8) – Min. 1M z
(female) (6), (7) – chassis
HM-CN1 (female) (6), (7)
ground
(female) (10), (11), HM-CN1
ORB-A (female) (10), (11) – Min. 1M z
(female) (19), (20) – chassis
HM-CN1 (female) (19), (20)
ground
Wiring harness between Resistance between ORB-A
ORB-A (female) (2) – HM- (female) (2), HM-CN2A (fe- Min. 1M z
CN2A (female) (17) male) (17) – chassis ground
ORB-B (female) (1) – HM- (female) (1) – HM-CN4B (fe-
CN4B (female) (4) and be- male) (4) and between ORB- Min. 1M z
tween ORB-B (female) (2) – B (female) (2) – HM-CN4B
HM-CN4B (female) (10) (female) (10)
7
Ground fault or short circuit CN4B (female) (4) and be- male) (4) and between ORB- Min. 1M z
in wiring harness tween ORB-B (female) (3) – B (female) (3) – HM-CN4B
Probable cause HM-CN4B (female) (3) (female) (3)
and standard value
when normal
CN4B (female) (10) and be- male) (10) and between Min. 1M z
tween ORB-B (female) (3) – ORB-B (female) (3) – HM-
HM-CN4B (female) (3) CN4B (female) (3)
Wiring harness between Resistance between ORB-A
ORB-A (female) (7), (8) – (female) (7), (8) – HM-CN1
HM-CN1 (female) (6), (7) (female) (6), (7) and be-
Min. 1M z
and between ORB-A (fe- tween ORB-A (female) (10),
male) (10), (11) – HM-CN1 (11) – HM-CN1 (female)
(female) (19), (20) (19), (20)
ORB-A (female) (2) – HM-
(female) (2) – HM-CN2A (fe-
CN2A (female) (17) and be-
male) (17) and between Min. 1M z
tween ORB-A (female) (10),
ORB-A (female) (10), (11) –
(11) – HM-CN1 (female)
HM-CN1 (female) (19), (20)
(19), (20)
and ORB-B.
20-1030 HD465-7, HD605-7

(10)

Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (1) – HM- male) (1), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-B
ORB-B (female) (2) – HM- (female) (2), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (3) – HM- male) (3), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-A (fe-
ORB-A (female) (2) – HM- male) (2), HM-CN2A (fe- Max. 1 V
CN2A (female) (17) male) (17) – chassis ground
Probable cause 1) Turn starting switch ON.
and standard value About 3 minutes after the VHMS controller is turned ON, judge by
when normal 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

(10)
b) Abnormality in downloading into PC or setting of PC
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set 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)
Resistance Max. 1 z
1 fective contact) (9) – VHMS (female) (B)
aWiring harness for down- Wiring harness between HM-CN4A (female)
loading in cab Resistance Max. 1 z
(10) – VHMS (female) (C)
Resistance Max. 1 z
(11) – VHMS (female) (D)
2) Disconnect connectors HM-CN4A and VHMS.
HM-CN4A (female) (9) – CN4A (female) (9), VHMS
Min. 1M z
VHMS (female) (B) (female) (B) – chassis
ground
Probable cause HM-CN4A (female) (10) – CN4A (female) (10), VHMS
Min. 1M z
and standard value VHMS (female) (C) (female) (C) – chassis
when normal ground
HM-CN4A (female) (11) – CN4A (female) (11), VHMS
Min. 1M z
Ground fault or short circuit VHMS (female) (D) (female) (D) – chassis
in wiring harness ground
2
aWiring harness for down- Wiring harness between Resistance between HM-
loading inside cab HM-CN4A (female) (9) – CN4A (female) (9) – VHMS
VHMS (female) (B) and be- (female) (B) and between Min. 1M z
tween HM-CN4A (female) HM-CN4A (female) (10) –
(10) – VHMS (female) (C) VHMS (female) (C)
HM-CN4A (female) (9) – CN4A (female) (9) – VHMS
VHMS (female) (B) and be- (female) (B) and between Min. 1M z
(11) – VHMS (female) (D) VHMS (female) (D)
HM-CN4A (female) (10) – CN4A (female) (10) – VHMS
VHMS (female) (C) and be- (female) (C) and between Min. 1M z
(11) – VHMS (female) (D) VHMS (female) (D)
20-1032 HD465-7, HD605-7

(10)

2) Disconnect connectors VHMS and VDL.
ness (Disconnection or de- Wiring harness between VHMS (male) (B) –
Resistance Max. 1 z
3 fective contact) VDL (female) (B)
aWiring harness for down- Wiring harness between VHMS (male) (C) –
loading inside cab Resistance Max. 1 z
VDL (female) (C)
Wiring harness between VHMS (male) (D) –
Resistance Max. 1 z
VDL (female) (D)
2) Disconnect connectors VHMS and VDL.
Wiring harness between Resistance between VHMS
VHMS (male) (B) – VDL (fe- (male) (B) – VDL (female) Min. 1M z
male) (B) (B) – chassis ground
Probable cause
VHMS (male) (C) – VDL (fe- (male) (C) – VDL (female) Min. 1M z
and standard value
male) (C) (C) – chassis ground
when normal
VHMS (male) (D) – VDL (fe- (male) (D) – VDL (female) Min. 1M z
male) (D) (D) – chassis ground
Ground fault or short circuit
in wiring harness Wiring harness between Resistance between VHMS
4
aWiring harness for down- VHMS (male) (B) – VDL (fe- (male) (B) – VDL (female)
loading outside cab male) (B) and between (B) and between VHMS Min. 1M z
VHMS (male) (C) – VDL (fe- (male) (C) – VDL (female)
male) (C) (C)
Wiring harness between Resistance betweenVHMS
VHMS (male) (B) – VDL (fe- (male) (B) – VDL (female)
male) (B) and between (B) and between VHMS Min. 1M z
VHMS (female) (D) – VDL (male) (D) – VDL (female)
(male) (D) (D)
VHMS (male) (C) – VDL (fe- (male) (C) – VDL (female)
male) (C) and between (C) and between VHMS Min. 1M z
VHMS (male) (D) – VDL (fe- (male) (D) – VDL (female)
male) (D) (D)
HD465-7, HD605-7 20-1033

(10)
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER

(DATA ARE NOT SAVED)
Action code Failure code Controller code Abnormality in saving data in VHMS controller
Trouble (Data are not saved)
Not set Not set Not set a LED of VHMS counts up and operates normally
• Data are not saved in the VHMS controller.
Contents of trouble
aPower is kept turned off.
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 z
(7) – fuse terminal BT-2 (29)
and standard value Disconnection in wiring har-
when normal 1 ness (Disconnection or de- *1) After the starting switch is turned to the OFF position, the LED of
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

(10)
HD465-7, HD605-7 20-1035

(5)
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW

(WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT
IS NORMAL)
Action code Failure code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring instrument
Not set Not set Not set 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

(10)
TROUBLESHOOTING OF ASR
CONTROLLER SYSTEM
(ASR MODE)
Electrical system diagram related ASR control ........................................................................................ 20-1052

Information in troubleshooting table...................................................................................................... 20-1053
Phenomenon 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 (Hot short) (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 (Hot short) (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 (Hot short) (KY).......................................................................................... 20-1081
[DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082
HD465-7, HD605-7 20-1051

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
20-1052 HD465-7, HD605-7

(5)

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

1
• Disconnection
• Ground fault
• Short circuit
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.
4
side.
• If connector No. has marks of "male" and "female", disconnect
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.
side.
HD465-7, HD605-7 20-1053

(10)
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.





MW Sliding
NS Overheat
20-1054 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDDAKA]
[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Trouble ASR system switch system: Disconnection (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) –
Resistance Max. 1 z
harness ASR (female) (3)
1
(Disconnection or defective 1) Turn starting switch OFF.
contact) 2) Disconnect connectors ASR and DPC2B.
Resistance Max. 1 z
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
switch When ASR system switch is Yes
normal
replaced with normal one, does
condition become normal? System switch is
No
defective
3 Defective machine monitor
Between DPC2B (3) – ASR system switch ON Voltage 20 – 30 V
chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) – ASR system switch ON Voltage Max. 1 V
chassis ground ASR system switch OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1055

(10)
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.
1 Hot short in wiring harness DPC2B (female) (3) – ASR male) (3), ASR (female) (3) – Max. 1 V
DPC2B (female) (9) – ASR male) (9), ASR (female) (2) – Max. 1 V
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
When ASR system switch is re- Yes
normal
placed with normal one, does con-
dition become normal? System switch is
No
defective
Between DPC2B (3) – ASR system switch ON Voltage 20 – 30 V
chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) – ASR system switch ON Voltage Max. 1 V
chassis ground ASR system switch OFF Voltage 20 – 30 V
20-1056 HD465-7, HD605-7

(10)
[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 ASR1 (female) (3)
ASR1 (female) (2)
Resistance Max. 1 z
– ASR1 (female) (1)
Wiring harness between Resistance between BRC2
Ground fault in wiring har- BRC2 (female) (16) – ASR1 (female) (16), ASR 1 (female) Min. 1 Mz
2
ness (female) (3) (3) – chassis ground
BRC3A (female) (7) – ASR1 (female) (7), ASR1 (female) Min. 1 Mz
Possible causes
and standard value
in normal state
3 Hot short in wiring harness Wiring harness between Voltage between BRC2
BRC2 (female) (16) – ASR1 (female) (16), ASR1 (female) Max. 1 V
Wiring harness between Voltage between BRC3A
BRC3A (female) (7) – ASR1 (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 ASR1 (3) – (1) Voltage 4.6 – 5.4 V
Between ASR1 (2) – (1) Voltage 2–3V
2) Disconnect connectors BRC2 and RTL.
5 Defective retarder controller
Between BRC1 (16) – BRC3A (16) Voltage 4.6 – 5.4 V
Between BRC3A (7) – (16) Voltage 2–3V
HD465-7, HD605-7 20-1057

(10)
20-1058 HD465-7, HD605-7

(5)
[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) – (2) Resistance 950 – 1,450 z
Between WSRR (male) (1), (2) – 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 WSRR (female) (1) Resistance Max. 1 z
contact)
Resistance Max. 1 z
– WSRR (female) (2)
3 Defective retarder controller 3) Connect T-adapter.
HD465-7, HD605-7 20-1059

(10)
[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) – (2) Resistance 950 – 1,450 z
Between WSRR (male) (1), (2) – chassis
ground
2
Possible causes
and standard value BRC3A (female) (3) – (female) (3), WSRR (female) Min. 1 Mz
in normal state WSRR (female) (1) (1) – chassis ground
ness
BRC3A (female) (3) – male) (3), WSRR (female) (1) Max. 1 V
WSRR (female) (1) – chassis ground
20-1060 HD465-7, HD605-7

(10)
[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) – (2) Resistance 950 – 1,450 z
Between WSRL (male) (1), (2) – 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) –
WSRL (female) (1)
contact)
Resistance Max. 1 z
– WSRL (female) (2)
HD465-7, HD605-7 20-1061

(10)
[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) – (2) Resistance 950 – 1,450 z
Between WSRL (male) (1), (2) – chassis
ground
2
Possible causes
and standard value BRC3A (female) (3) – WSRL (female) (3), WSRL (female) Min. 1 Mz
in normal state (female) (1) (1) – chassis ground
ness
Wiring harness between Voltage between BRC3A
BRC3A (female) (3) – WSRL (female) (3), WSRL (female) Max. 1 V
20-1062 HD465-7, HD605-7

(10)
TROUBLESHOOTING [dLT3LC]
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:

*SEE SEPARATE LIST (LC)
Action code Failure 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 3) Connect T-adapter.
1
output shaft speed sensor
2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5.
Ground fault in wiring har- Wiring harness between
2 Resistance between BRC3A
ness ATC3A (female) (3) –
(female) (13), ATC3A (female)
BRC3A (female) (13) – PM5 Min. 1 Mz
Possible causes (female) (7) – CN5 (female) (3), PM5 (female) (7), CN5 (fe-
and standard value (1) male) (1) – chassis ground
in normal state
2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5.
Wiring harness between Voltage between ATC3A
ATC3A (female) (3) – (female) (3), BRC3A (female)
BRC3A (female) (13) – PM5 Max. 1 V
(female) (7) – CN5 (female) (13), PM5 (female) (7), CN5
(1) (female) (1) – chassis ground

Defective transmission con- 2) Disconnect connector BRC3A.
troller
HD465-7, HD605-7 20-1063

(10)
TROUBLESHOOTING [dLT3LC]
20-1064 HD465-7, HD605-7

(5)
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 z
– (2) Oil pressure OFF Resistance Min. 1 Mz
2) Disconnect connectors BRC5B and ASR7.
Ground fault in wiring 4) Connect connector.
harness
Possible causes
and standard value Wiring harness between Resistance between BRC5B
in normal state BRC5B (female) (8) – ASR7 (female) (8), ASR7 (female) Max. 1 z
Wiring harness between Voltage between BRC5B
BRC5B (female) (8) – ASR7 (female) (8), ASR7 (female) Max. 1 V
2) Disconnect connectors BRC5B and BRC2.
Between BRC5B (8) – BRC2 Oil pressure ON Voltage Max. 1 V
(21) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1065

(10)
TROUBLESHOOTING [DWNBK4]
20-1066 HD465-7, HD605-7

(5)
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) – (2) Resistance 10 – 30 z
Between ASR2 (1), (2) – chassis ground Resistance Min. 1 Mz
Possible causes
and standard value
2) Disconnect connectors BRC2 and ASR2.
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (2) –
Resistance Max. 1 z
defective contact) ASR2 (female) (1)
Resistance Max. 1 z
ASR2 (female) (2)
HD465-7, HD605-7 20-1067

(10)
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
Possible causes
and standard value
Ground fault or short BRC2 (female) (2) – ASR2 (female) (2), ASR2 (female) Max. 1 z
2 (female) (1) (1) – chassis ground
circuit in wiring harness
Between wiring harness be-
Resistance between BRC2
tween BRC2 (female) (2) –
(female) (2), ASR2 (female)
ASR2 (female) (1) and be- Max. 1 z
(1) – BRC2 (female) (13),
tween BRC2 (female) (13) –
ASR2 (female) (2)
ASR2 (female) (2)
20-1068 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DWNBKY]
[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE

(HOT SHORT) (KY)
Action code Failure code Controller code Shut-off solenoid valve: Short circuit with power source
Trouble
E01 DWNBKY BK (Hot short) (KY)
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.
4) Connect connector
Wiring harness between Voltage between BRC2
HD465-7, HD605-7 20-1069

(10)
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) – ASR7 (female) (8), ASR7 (female) Max. 1 z
20-1070 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX17K4]
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

UNCONTROLLABLE (K4)
Action code Failure 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
Ground fault in wiring 4) Connect connector.
Possible causes harness
HD465-7, HD605-7 20-1071

(10)
20-1072 HD465-7, HD605-7

(5)
[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 ASR3 (female) (1) Resistance Max. 1 z
contact)
Resistance Max. 1 z
ASR3 (female) (2)
HD465-7, HD605-7 20-1073

(10)
[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
Ground fault or short
2 BRC2 (female) (9) – ASR3 (female) (9), ASR3 (female) Min. 1 Mz
circuit in wiring harness
Wiring harness between BRC2 (female) (9) – ASR3 (fe-
male) (1) and between BRC2 (female) (19) – ASR3 (fe- Min. 1 Mz
male) (2)
20-1074 HD465-7, HD605-7

(10)
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Trouble
E01 DX17KY BK Short circuit with power source (Hot short) (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
male) (2)
HD465-7, HD605-7 20-1075

(10)
[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

(10)
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

UNCONTROLLABLE (K4)
Action code Failure 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

(10)
20-1078 HD465-7, HD605-7

(5)
[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) –
Resistance Max. 1 z
defective contact) ASR4 (female) (1)
Resistance Max. 1 z
ASR4 (female) (2)
HD465-7, HD605-7 20-1079

(10)
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT (KB)
Action code Failure 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.
in normal state
Ground fault or short
2 BRC2 (female) (8) – ASR4 (female) (8), ASR4 (female) Min. 1 Mz
circuit in wiring harness (female) (1) (1) – chassis ground
male) (2)
20-1080 HD465-7, HD605-7

(10)
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Action code Failure code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KY BK circuit with power source (Hot short) (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.
male) (2)
HD465-7, HD605-7 20-1081

(10)
[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

(10)
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

(2)
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

(10)
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

(2)
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)
• There is hunting.
• Look-up lamp flashes.

• Is the oil level in the transmission case correct?
• Is any failure code related power trains displayed?
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)

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

(10)
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

a Shifts up on downhill slopes.
Causes Remedy
Slipping or damage of torque converter lock-up clutch
a 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

(10)
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 idle 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
A
No. C
Problems See b. 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

(10)
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

Defective lock-up ECMV solenoid
Cracked lock-up clutch case

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

(10)
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.
a Remove all the mud and dirt from around the ECMV, and clean it before replacing.
a 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
a
H clutch disc worn or seized, seal ring worn
b
L clutch disc worn or seized, seal ring worn
c
4th clutch disc worn or seized, seal ring worn
HD465-7, HD605-7
d
3rd clutch disc worn or seized, seal ring worn
TROUBLESHOOTING
e
2nd clutch disc worn or seized, seal ring worn
f
1st clutch disc worn or seized, seal ring worn
g
R clutch disc worn or seized, seal ring worn
h
Defective operation of H clutch ECMV
i
Defective operation of L clutch ECMV
j
Defective operation of 4th clutch ECMV
k
Defective operation of 3rd clutch ECMV
l
Defective operation of 2nd clutch ECMV
m
Defective operation of 1st clutch ECMV
n
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

(2)
Causes
C
Clogged strainer
b
c
Defective pump
HD465-7, HD605-7
d
Defective oil tightness in rotating clutch
TROUBLESHOOTING
e
Defective shaft seal ring in rotating clutch circuit
f
Drop in set pressure of main relief valve
g
H clutch disc worn or defective seal ring, worn groove
h
L clutch disc worn or defective seal ring, worn groove
i
4th clutch disc worn or defective seal ring, worn groove
j
3rd clutch disc worn or defective seal ring, worn groove
k
2nd clutch disc worn or defective seal ring, worn groove
l
1st clutch disc worn or defective seal ring, worn groove
m
R clutch disc worn or defective seal ring, worn groove
n
Defective operation of H clutch ECMV
o
Defective operation of L clutch ECMV
p
Defective operation of 4th clutch ECMV
q
Defective operation of 3rd clutch ECMV
r
Defective operation of 2nd clutch ECMV
s
Defective operation of 1st clutch ECMV
t
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.
a If oil temperature is normal but oil temperature gauge on machine goes above operating range.
odefective 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-pump converter
a b c d e f
Remedy
No. C
Problems
1 Pump makes abnormal noise when oil temperature is low
2 High idle and low idle 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

(10)
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

(2)
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

(10)
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

(10)
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 idle 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 idle
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

(10)
H-13 Steering wheel does not work

• Is there any external oil leakage between
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 side
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 idle, 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 idle
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 A
Leakage of air inside steering cylinder
HD465-7, HD605-7 20-1117

(10)
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 between
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 1 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 idle
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 – 10 are normal but dump body lifting speed is slow
20-1118 HD465-7, HD605-7

(10)
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 idle
7
valve
Hoist circuit pressure is too high at engine low idle or
8
pressure rises to relief pressure (Items 1 - 5 normal)
9 Works when engine is at low idle
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

(10)
H-17 Excessive hydraulic drift of dump body

• Is 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

(10)
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 coolant, or water spurts back, or water level goes down .................................................20-1178
S-12 Oil pressure warning lamp lights up (drop in oil pressure).............................................................20-1179
S-13 Oil level rises .................................................................................................................................20-1180
S-14 Coolant 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

(10)
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 coolant 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, coolant, 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

(10)
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 (A) + (B) in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in (B) 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 (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) 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

(10)
• 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
• Defective HPI sensor
• Defective HPI actuator
• Normal output is not applied
a See Troubleshooting S-6
20-1154 HD465-7, HD605-7

(10)
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 shows 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

(10)
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 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 Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with
starting motor, Fuel pump outlet port coupler is pushed, air comes out together with fuel
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 idle? 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

(10)
TROUBLESHOOTING S-1
Causes (*1) If the following failure codes are displayed, carry out
the troubleshooting in "ENG mode". (If any of the
following failure 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

[C112LK]:Abnormality in timing rail actuator
Defective atmospheric pressure sensor
Defective coolant temperature sensor

Defective fuel pump pressure sensor
Defective timing rail pressure 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

(10)
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)
Defective starting motor safety relay or safety switch

a See the manual for the machine.
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
(*1)
When terminal B and terminal C of safety relay are connected, engine starts
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

(10)
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

(10)
TROUBLESHOOTING S-2
(*1) If the following failure codes are displayed, carry out

Causes probably the cause of the trouble. In this case,
Defective intake manifold temperature sensor
Defective coolant temperature sensor


Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1161

(10)
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
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

(10)
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 coolant 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

(10)
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



(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 idle 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

(10)
TROUBLESHOOTING S-3
Air leakage from piping between turbocharger and cylinder head

Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1165

(10)
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.
• Problem in power train (troubleshooting for machine)
Broken dynamic valve system (valve, rocker arm, etc.)
Defective in power train (troubleshooting for machine)

Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)

• Low power source voltage of controller

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 warning 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

(10)
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

(10)
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 idle
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

(10)
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
[C318LK]: Abnormality in fuel pump actuator
this case, inspect the other devices for the cause.)
(*1) If the following failure code is displayed, carry out
played, it is not probably the cause of the trouble. In

the troubleshooting in "ENG mode". (If it is not dis-
(10)
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 Causes

• Improper fuel used
(if non-specified fuel is used, output drops)
• There is overheating

a See Troubleshooting S-14.
Improper adjustment of valve clearance


Seized turbocharger, interference

• Wrong pare number of controller

• High fuel temperature

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 idle 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

(10)
TROUBLESHOOTING S-6


Defective controller calibration data

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
—
—
HD465-7, HD605-7 20-1171

(10)
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

(10)
TROUBLESHOOTING S-7

[C112LK]: Abnormality in timing rail actuator
(*2) If an failure code of the timing rail pressure sensor
system is displayed, carry out the troubleshooting in
"EA mode".
HD465-7, HD605-7 20-1173

(10)
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 idle for more
than 20 minutes continuously (both low and high idle).
Causes
General causes why oil consumption is excessive

• Abnormal combustion of oil
• External leakage of oil
Worn seal at turbine end

Worn seal at blower end
• Wear of parts in lubrication system
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 coolant
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

(10)
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
• Improper fuel used 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 warning lamp lights up (machines equipped with warning 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
Replace
Correct
Clean
Clean
Clean
Remedy
20-1176 HD465-7, HD605-7

(10)
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

Leakage of fuel inside head cover


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 failure 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

(10)
S-11 Oil is in coolant, or water spurts back, or coolant level goes down
General causes why oil is in coolant
• 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 coolant (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

(10)
S-12 Oil pressure warning lamp lights up (drop in oil pressure)

General causes why oil pressure warning 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
Coolant, fuel in oil

Clogged oil filter
Questions
Non-specified oil is being used

Engine oil pressure warning lamp lights up
Lights up at low idle
Condition when oil pressure warning lamp Lights up at low, high idle
lights up. Lights up on slopes
Sometimes lights up
Oil level warning lamp lights up (machines equipped with warning 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 warning 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

(10)
S-13 Oil level rises

General causes why oil level rises
• Coolant in oil (milky white)
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of coolant or oil from other component Causes
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

Defective fuel pump seal
Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in coolant (*1)
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appear, or coolant (*1) 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, coolant 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
Correct
Correct
Correct
Remedy
(*1) If there is oil in coolant, carry out Troubleshooting S-11.
20-1180 HD465-7, HD605-7

(10)
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant 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 coolant 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
Broken water pump

Lack of coolant
machine)
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Coolant temperature gauge
Does not go down from red range
Radiator coolant level warning lamp lights up (machines equipped with warning lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on coolant
Excessive air bubbles inside radiator, coolant 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
Coolant 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
Coolant flows out from overflow hose
Power train oil temperature enters red range faster than engine coolant 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 coolant 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

(10)
S-15 Abnormal noise is made

General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion noise
• Air sucked in from intake system Causes
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
Seized turbocharger, internal interference (*1)
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt 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
(*1) Judge if the noise is an internal noise or an external noise.
20-1182 HD465-7, HD605-7

(10)
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 Causes
• Abnormal combustion
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
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idle

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

(10)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
Electrical system diagram related to emergency steering control ............................................................. 20-1202

Information in troubleshooting table .......................................................................................................... 20-1203
E-1 Emergency steering system does not operate ................................................................................. 20-1205
HD465-7, HD605-7 20-1201

(11)
ELECTRICAL SYSTEM DIAGRAM RELATED TO
TROUBLESHOOTING EMERGENCY STEERING CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL

20-1202 HD465-7, HD605-7

(11)

Trouble Trouble in machine
Related
Information related to detected trouble or troubleshooting
information

1
• Disconnection
• Ground fault
Harness which is not connected to chassis ground circuit is in contact
2
with chassis ground circuit.
Possible causes • Short circuit
Possible causes of trouble
and standard Independent harnesses are in contact with each other abnormally.
(Given numbers are refer-
value in normal 3
ence numbers, which do
state <Precautions for troubleshooting>
not indicate priority)
1) Method of indicating connector No. and handling of T-adapter
4 connector and insert T-adapters in both male side and female side.
• If connector No. has marks of "male" and "female", disconnect con-
nector and connect T-adapter to only male side or female side.
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.
side.
HD465-7, HD605-7 20-1203

(11)

20-1204 HD465-7, HD605-7

(11)
TROUBLESHOOTING E-1
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE
1) When emergency steering switch is pressed, emergency steering system does not operate.
Trouble
2) Automatic emergency steering system does not operate.
aSee Operation and Maintenance Manual, Operation, Testing and adjusting before starting engine, In-
Related spection of emergency steering and Inspection of automatic emergency steering.
information • When parking brake is released, voltage is generated at pin H01 (2). When flow on flow switch is lost
and flow switch is turned ON, voltage is generated at pin H01 (1).

Defective fuse BT2-(26) or If fuse is broken, circuit probably has ground fault. (Carry out trouble-
1
BT3-(16) shooting for cause 8.)
aPrepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective emergency Terminals of switch Emergency steering switch Resistance
2
steering switch
Between input terminal ON Max. 1 z
– output terminal OFF Min. 1 Mz
1) Turn starting switch OFF and disconnect parking brake connector
PSW (or HTA).
2) Start engine and apply retarder brake, then carry out troubleshooting.
Defective parking brake PSW (male) Parking brake switch Resistance
3
switch
When parking brake is released Max. 1 z
Between (1) – (2) When parking brake is operated
Min. 1 Mz
(applied)
aPrepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
Between inlet terminal from fuse BT2 (26) –
Voltage 20 – 30V
and standard aEven if starting switch is turned ON, parking brake is not released until
value in normal parking brake switch is turned ON (operated) and OFF once. (While
state parking brake is released, contacts of parking brake should be connect-
ed to each other.)
1) Start engine, charge accumulator, apply retarder brake, and stop en-
Defective emergency gine.
steering timer
3) Turn parking brake switch OFF (Release).
Between inlet terminal from flow switch – chas-
Voltage 20 – 30V
sis ground
Between emergency steering relay drive termi-
Voltage 20 – 30V
Between switch ground terminal – chassis
Resistance Max. 1 z
ground (GND 2)
2) Turn emergency steering switch ON and carry out troubleshooting.
Between motor (+) terminal – chassis ground Voltage 20 – 30V
5 Defective starting motor
Between motor (-) terminal – chassis ground Resistance Max. 1 z
HD465-7, HD605-7 20-1205

(11)
TROUBLESHOOTING E-1

2) Turn emergency steering switch ON and carry out troubleshooting.
Between emergency steering relay terminal B –
Voltage 20 – 30V
chassis ground
Between emergency steering relay terminal M –
Defective emergency Voltage 20 – 30V
chassis ground
6 steering relay (Both are
same) Between emergency steering relay drive termi-
Voltage 20 – 30V
Between emergency steering relay ground ter-
Resistance Max. 1 z
minal – chassis ground
Wiring harness between emergency steering re-
Resistance Max. 1 z
lay terminal M – motor (+) terminal
Resistance Max. 1 z
lay drive terminal – timer drive terminal
Wiring harness between fuse BT2 (26) – timer
Resistance Max. 1 z
Disconnection in wiring power supply input terminal
Possible causes
harness (Disconnection in Wiring harness between fuse BT3 (16) – PSW
and standard 7 Resistance Max. 1 z
wiring or defective contact (female) (1)
value in normal
in connector)
state Wiring harness between PSW (female) (2) –
Resistance Max. 1 z
CJN – H01 (female) (2)
Wiring harness between H01 (female) (1) – timer
Resistance Max. 1 z
inlet terminal
Resistance Max. 1 z
lays (All of 4)
Resistance Max. 1 z
lay (-) terminal – CJK – chassis ground
lay terminal M – motor (+) terminal
lay drive terminal – timer drive terminal
Ground fault in wiring
Wiring harness between fuse BT2 (26) – timer
8 harness (Short circuit with Resistance Min. 1 Mz
power supply input terminal
GND circuit)
Wiring harness between fuse BT3 (16) – PSW
(female) (1)
Wiring harness between PSW (female) (2) –
CJN – H01 (female) (2)
Wiring harness between H01 (female) (1) – timer
inlet terminal
a If "the emergency steering system operates by itself (while the switch is not turned ON)", check the following
possible causes.
1) The emergency steering relay is fixed to the ON position because of some vibration. (Replace the
emergency steering relay.)
2) The voltage at the (+) terminal of the emergency steering relay is 20 – 30 V. (This terminal should be
grounded.)
3) The wiring on the M side of the emergency steering relay is in contact with the wiring on the B side.
(Open the battery box and check the wiring.)
4) The parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.)
5) The steering flow switch is stuck. (Replace the steering flow switch.)
20-1206 HD465-7, HD605-7

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TROUBLESHOOTING E-1
a How to distinguish the emergency steering relays and the ordinary battery relay.
When the battery box is opened, the 2 relays on the left side (on the front side of the machine) are the emer-
gency steering relays.
HD465-7, HD605-7 20-1207

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TROUBLESHOOTING OF ABS CONTROLLER
SYSTEM (ABS MODE) (IF EQUIPPED)
Electrical system diagram related ABS control ........................................................................................ 20-1252
Information in troubleshooting table .......................................................................................................... 20-1254
Phenomenon code table ........................................................................................................................... 20-1255
[D1E5KZ] ABS cut relay: Disconnection or short circuit (KZ)................................................................ 20-1256
[DBC0KK] ABS controller: Supply voltage reduction (KK) ..................................................................... 20-1258
[DBC1KK] ABS controller main power line: Supply voltage reduction (KK) ........................................... 20-1259
[DBC2KK] ABS controller load power line: Supply voltage reduction (KK) ............................................ 20-1260
[DBC3KK] ABS controller battery direct power supply: Supply voltage reduction (KK) ......................... 20-1262
[DBC9KM] ABS controller wire wiring harness: Setting operation error (KM) ........................................ 20-1263
[DBCSKR] ABS controller S-NET communication: Defective communication (KR) ............................... 20-1264
[DDD9KA] ABS system switch: Disconnection (KA) .............................................................................. 20-1265
[DDD9KB] ABS system switch: Short circuit (KB) .................................................................................. 20-1266
[DHU6KX] ABS control valve pressure sensor front wheel right (FR):
Outside input signal range (KX) ....................................................................................... 20-1268
[DHU7KX] ABS control valve pressure sensor front wheel left (FL):
[DHU8KX] ABS control valve pressure sensor rear wheel right (RR):
[DHU9KX] ABS control valve pressure sensor rear wheel left (RL):
[dk11KX] Accelerator sensor: Outside input signal range (KX)............................................................ 20-1276
[DLF6KA] Wheel speed sensor front wheel right (FR): Disconnection (KA) ......................................... 20-1278
[DLF7KA] Wheel speed sensor front wheel left (FL): Disconnection (KA) ............................................ 20-1280
[dLF8KA] Wheel speed sensor rear wheel right (RR): Disconnection (KA).......................................... 20-1282
[dLF9KA] Wheel speed sensor rear wheel left (RL): Disconnection (KA)............................................. 20-1284
[DWNDKZ] ABS cut valve (F): Disconnection or short circuit (KZ) ......................................................... 20-1286
[DWNDMA] ABS cut valve (F): Malfunction (MA) .................................................................................... 20-1288
[DWNEKZ] ABS cut valve (R): Disconnection or short circuit (KZ) ......................................................... 20-1290
[DWNEMA] ABS cut valve (R): Malfunction (MA) .................................................................................... 20-1292
[DX21KA] ABS control valve front wheel right (FR): Disconnection (KA).............................................. 20-1293
[DX21KB] ABS control valve front wheel right (FR): Short circuit (KB) ................................................. 20-1294
[DX21KY] ABS control valve front wheel right (FR): Short-circuited to power supply (KY) ................... 20-1295
[DX21MA] ABS control valve front wheel right (FR): Malfunction (MA) ................................................. 20-1296
[DX22KA] ABS control valve front wheel left (FL): Disconnection (KA)................................................. 20-1297
[DX22KB] ABS control valve front wheel left (FL): Short circuit (KB) .................................................... 20-1298
[DX22KY] ABS control valve front wheel left (FL): Short-circuited to power supply (KY)...................... 20-1299
[DX22MA] ABS control valve front wheel left (FL): Malfunction (MA) .................................................... 20-1300
[DX23KA] ABS control valve rear wheel right (RR): Disconnection (KA) .............................................. 20-1301
[DX23KB] ABS control valve rear wheel right (RR): Short circuit (KB).................................................. 20-1302
[DX23KY] ABS control valve rear wheel right (RR): Short-circuited to power supply (KY) ................... 20-1303
[DX23MA] ABS control valve rear wheel right (RR): Malfunction (MA).................................................. 20-1304
[DX24KA] ABS control valve rear wheel left (RL): Disconnection (KA) ................................................. 20-1305
[DX24KB] ABS control valve rear wheel left (RL): Short circuit (KB)..................................................... 20-1306
[DX24KY] ABS control valve rear wheel left (RL): Short-circuited with power supply (KY)................... 20-1307
[DX24MA] ABS control valve rear wheel left (RL): Malfunction (MA)..................................................... 20-1308
[DX25MA] ABS control valve (front wheel system): Malfunction (MA)................................................... 20-1309
[DX26MA] ABS control valve (rear wheel system): Malfunction (MA) ................................................... 20-1310
HD465-7, HD605-7 20-1251

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TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
20-1252 HD465-7, HD605-7

(12)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
HD465-7, HD605-7 20-1253

(12)

panel panel panel
Contents of trouble Contents of trouble detected by machine monitor or controller
Action of machine Action taken by controller to protect system or devices when machine monitor or controller detects trou-
monitor or controller ble
Problem that Problem that appears on machine as result of action taken by machine monitor or controller
appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting

1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
Wiring harness which is not connected to chassis ground circuit is in
2 contact with chassis ground circuit.
• Hot short
Wiring harness, which is not connected to power source (24 V) cir-
cuit, is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other abnor-
Possible causes Possible causes of troubles mally.
3
in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority.) (1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshoot-
ing, unless otherwise specified.
• if connector No. has no marks of "male" and "female", disconnect
4 side.
• If connector No. has marks of "male" and "female", disconnect
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as ex-
• Connect positive (+) lead to pin No. or wiring harness entered on
5
front side.
• Connect negative (-) lead to pin No. or wiring harness entered on
rear side side.
20-1254 HD465-7, HD605-7

(12)
Related circuit diagram

• Connector No.: Indicates (Model - Number of pins) and (Color).

Phenomenon Contents
code
KA Disconnection is wiring
KB Short circuit
KK Supply voltage reduction
KM Operation or setting error
KR Defective communication
KX Outside input signal range
KY Hot short (short-circuit with power source)
KZ Disconnection or short circuit
MA Malfunction
HD465-7, HD605-7 20-1255

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TROUBLESHOOTING [D1E5KZ]
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code ABS cut relay:

Trouble
E03 D1E5KZ ABS Disconnection or short circuit on ABS cut relay (KZ)
• Excessive current is conducted or no current is conducted as output is generated to ABS cut relay cir-
Contents of trouble cuit.
• Current is conducted after the output is turned off.
Action of controller • Stops ABS control.
Problem that • ABS doesn't work.
appears on machine • Usual brake is operable.
Related information

1) Turn off starting switch.
2) Disconnect connectors ABS1 and RABS.
ness
1 Wiring harness between ABS1 (female) (14) –
RABS (female) (1)
contact)
Between chassis ground – wiring harness
Resistance Max. 1 z
RABS (female) (2)
2
ness
Wiring harness between ABS1 (female) (14),
Possible causes Resistance Min. 1 Mz
RABS (female) (1) – chassis ground
and standard value
in normal state 1) Turn off starting switch.
3 Hot short on wiring harness 4) Connect the connector.
5) Turn on starting switch.
Voltage Max. 1 V
RABS (female) (1) – chassis ground
4 Defective ABS cut relay Replacing ABS cut relay restores the normal state.
2) Disconnect connector ABS1.
5 Defective ABS controller 3) Connect T-adapter.
Wiring harness between ABS1 (female) (14) – 250 –
Resistance
chassis ground 350 z
20-1256 HD465-7, HD605-7

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TROUBLESHOOTING [D1E5KZ]
HD465-7, HD605-7 20-1257

(12)
TROUBLESHOOTING [DBC0KK]
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)
Action code Failure code Controller code ABS controller: Supply voltage reduction in main and direct sup-
Trouble
E03 DBC0KK ABS ply voltage circuits (KK)
Contents of trouble • Both the main supply voltage and direct supply voltage circuits went below 17 V.
Related information

Disconnection in wiring har- 2) Disconnect connector ABS1.
1
contact) Wiring harness between ABS1 (female) (8),
Resistance Max. 1 z
Defective battery or defec- Battery voltage shall be 24 V minimum and specific gravity shall be
2
Possible causes tive charging 1.26.
and standard value
in normal state
3 Defective ABS controller
Wiring harness between ABS1 (female) (7) –
Voltage 20 – 30 V
ABS1 (female) (8), (16)
Voltage 20 – 30 V
(17) – ABS1 (female) (8), (16)
20-1258 HD465-7, HD605-7

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[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION

(KK)

Trouble ABS controller main power line: Supply voltage reduction (KK)
E03 DBC1KK ABS
• Difference of voltage between the main supply voltage circuit and direct supply voltage circuit became
Contents of trouble
5 V or greater.
Related information

in normal state (Disconnection or defective 5) Turn on starting switch.
contact)
Voltage 20 – 30 V
(17) – ABS1 (female) (8), (16)
Related electric circuit diagram
HD465-7, HD605-7 20-1259

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[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION

(KK)
Action code Failure code Controller code ABS controller load power line:
Trouble
E03 DBC2KK ABS Voltage reduction in solenoid supply voltage (KK)
• Solenoid supply voltage went 17 V or below while controller supply voltage circuit was operating nor-
Contents of trouble
mally.
Related information

1 Defective ABS cut relay Replace it with other relay to restore normal state.
ness 1 3) Connect T-adapter.
2 4) Turn on starting switch.
contact) Wiring harness between RABS (female) (5) –
Voltage 20 – 30 V
chassis ground
Disconnection in wiring har- 2) Disconnect connectors RABS and ABS1.
Possible causes ness 2 3) Connect T-adapter.
in normal state Wiring harness between RABS (female) (3) –
ABS1 (female) (9), (17)
2) Disconnect connectors ABS1 and ABS2.
4 Defective ABS controller 5) Turn on starting switch.
Voltage 20 – 30 V
ABS1 (female) (8), (16)
Voltage 20 – 30 V
ABS1 (female) (8), (16)
20-1260 HD465-7, HD605-7

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HD465-7, HD605-7 20-1261

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[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY

VOLTAGE REDUCTION (KK)
Action code Failure code Controller code ABS controller battery direct power supply:
Trouble
E03 DBC3KK ABS Supply voltage reduction (KK)
Contents of trouble • Voltage of battery direct power supply circuit went 5 V or below.
Action of controller • Continues ABS control.
Problem that
• Remains unchanged.
appears on machine
Related information

1
(Disconnection or defective 4) Turn on starting switch.
Possible causes contact) Wiring harness between ABS1 (female) (7) –
Voltage 20 – 30 V
and standard value ABS1 (female) (8), (16)
in normal state
2) Disconnect connectors ABS1 and ABS2.
2 Defective ABS controller 4) Turn on starting switch.
Voltage 20 – 30 V
ABS1 (female) (8), (16)
20-1262 HD465-7, HD605-7

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TROUBLESHOOTING [DBC9KM]
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION

ERROR (KM)

Trouble ABS controller wiring harness: Setting operation error (KM)
E03 DBC9KM ABS
• Connector-check signal to be entered at turning on of starting switch does not match the internal set-
Contents of trouble
ting of controller.
Related information

Wrong connection of con- 1) Turn off starting switch.
1
Possible causes troller connector Connectors ABS3A and ABS5A are appropriately installed.
and standard value 1) Turn off starting switch.
in normal state Disconnection in wiring har- 2) Disconnect connector ABS5A.
2
Wiring harness between ABS5A (female) (1) –
chassis ground
HD465-7, HD605-7 20-1263

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TROUBLESHOOTING [DBCSKR]
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE

COMMUNICATION (KR)
Action code Failure code Controller code ABS controller S-NET communication:
Trouble
E03 DBCSKR ABS Communication failure (KR)
Contents of trouble • Input of communication information from monitor to ABS controller is unavailable.
Related information

1
(Disconnection or defective 5) Turn on starting switch.
contact)
Possible causes Wiring harness between ABS4 (female) (6),
Voltage 6–9V
and standard value (12) – chassis ground
2 Defective ABS controller 4) Connect the connector.
Voltage 6–9V
20-1264 HD465-7, HD605-7

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TROUBLESHOOTING [DDD9KA]
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)

Trouble ABS system switch: Disconnection (KA)
E03 DDD9KA ABS
Contents of trouble • ON-input and OFF-input of ABS system switch were turned off.
Related information

2) Disconnect connectors ABS and DPC2B.
1 Hot short on wiring harness 3) Connect T-adapter.
Resistance Max. 1 z
ABS (female) (3)
2) Replace ABS system switch with a normal one.
Defective ABS system
Possible causes 2 Normal state System switch is nor-
switch mal
and standard value After replacing ABS system was not restored
in normal state switch with a normal one: Normal state System switch is defec-
was restored tive
Wiring harness be- Turn on ABS system
Voltage 20 – 30 V
tween DPC2B (fe- switch
male) (2) – chassis Turn off ABS system
switch
HD465-7, HD605-7 20-1265

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TROUBLESHOOTING [DDD9KB]
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)

Trouble ABS system switch: Short circuit (KB)
E03 DDD9KB ABS
Contents of trouble • ON-input and OFF-input of ABS system switch were turned on.
Related information

2) Disconnect connectors ABS and DPC2B.
1
ness
ABS (female) (3)
2) Replace ABS system switch with a normal one.
Defective ABS system
Possible causes 2 Normal state System switch is nor-
switch mal
and standard value After replacing ABS system was not restored
in normal state switch with a normal one: Normal state System switch is defec-
was restored tive
Wiring harness be- Turn on ABS system
Voltage 20 –30 V
tween DPC2B (fe- switch
male) (2) – chassis Turn off ABS system
switch
20-1266 HD465-7, HD605-7

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[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR):
OUTSIDE INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code ABS control valve pressure sensor front wheel right (FR):
Trouble Outside input signal range (KX)
E03 DHU6KX ABS
• Input voltage to ABS control valve pressure sensor (FR) signal circuit went 0.3 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS2, ABS3A and BPFR.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16)
1 – BPFR (female) (1)
contact) Wiring harness between ABS3A (female) (9) –
Resistance Max. 1 z
BPFR (female) (3)
Resistance Max. 1 z
BPFR (female) (2)
2) Disconnect connectors ABS3A and BPFR.
2
ness
Possible causes Wiring harness between ABS3A (female) (9),
and standard value BPFR (female) (3) – chassis ground
2) Disconnect connectors ABS3A and BPFR.
Wiring harness between ABS3A (female) (9),
Voltage Max. 4.7 V
BPFR (female) (3) – chassis ground
Replacing pressure sensor (Front wheel right: BPFR) with (Front wheel
4 Defective sensor
left: BPFL) restores the normal state.
2) Disconnect connector ABS3A.
5 Defective ABS control 4) Connect the connector.
Across terminals between ABS3A (female) (9)
– ABS3A (female) (16)
20-1268 HD465-7, HD605-7

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HD465-7, HD605-7 20-1269

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[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL):
Action code Failure code Controller code ABS control valve pressure sensor front wheel left (FL):
Trouble
E03 DHU7KX ABS Outside input signal range (KX)
• Input voltage to ABS control valve pressure sensor (FL) signal circuit went 0.3 V or below or 4.7 V or
Contents of trouble
above.
Related information

1) Turn off the starting switch.
2) Disconnect connectors ABS2, ABS3 and BPFL.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16)
1 – BPFL (female) (1)
contact) Wiring harness between ABS3A (female) (10)
Resistance Max. 1 z
– BPFL (female) (3)
Resistance Max. 1 z
BPFL (female) (2)
1) Turn off the starting switch.
2) Disconnect connectors ABS3 and BPFL.
2
ness
Possible causes Wiring harness between ABS3A (female) (10),
and standard value BPFL (female) (3) – chassis ground
2) Disconnect connectors ABS3A and BPFL.
Voltage Max. 4.7 V
BPFL (female) (3) – chassis ground
Replacing pressure sensor (Front wheel left: BPFL) with (Front wheel
4 Defective pressure sensor
right: BPFR) restores the normal state.
5 Defective ABS control 4) Connect the connector.
Across terminals between ABS3A (female)
(10) – ABS3A (female) (16)
20-1270 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1271

(12)
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR):
Action code Failure code Controller code ABS control valve pressure sensor rear wheel right (RR):
Trouble
• Input voltage to ABS control valve pressure sensor (RR) signal circuit went 0.5 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS1, ABS3A and BPRR.
ness 1 Wiring harness between ABS3A (female) (16)
Resistance Max. 1 z
1 (Pressure sensor circuit) – BPRR (female) (1)
(Disconnection or defective Wiring harness between ABS3A (female) (19)
– BPRR (female) (3)
Resistance Max. 1 z
BPRR (female) (2)
Ground fault in wiring har- 2) Disconnect connectors ABS3A and BPRR.
2 ness 3) Connect T-adapter.
(Pressure sensor circuit) Wiring harness between ABS3A (female) (19),
BPRR (female) (3) – chassis ground
2) Disconnect connectors ABS3A and BPRR.
Hot short on wiring harness 4) Connect the connector.
3
(Pressure sensor circuit) 5) Turn on starting switch.
Possible causes Voltage Max. 4.7 V
BPRR (female) (3) – chassis ground
and standard value
2) Disconnect connectors ABS5A and S01F.
ness 2
4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) –
Resistance Max. 1 z
(Disconnection or defective S01F(female) (1)
contact)
Wiring harness between S01M (male) (2) –
Resistance Max. 1 z
S01F (female) (2)
2) Disconnect connectors ABS5A and BRC5A.
ness 3
5 (Retarder switch circuit) Wiring harness between ABS5A (female) (5) –
Resistance Max. 1 z
(Disconnection or defective BRC5A (F) (female) (4)
contact)
Wiring harness between BRC5A (M) (male) (4)
Resistance Max. 1 z
– BRC5A (F) (female) (4)
Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel
left: BPRL) restores the normal state.
(19) – ABS3A (female) (16)
20-1272 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1273

(12)
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL):
Action code Failure code Controller code ABS control valve pressure sensor rear wheel left (RL):
Trouble
• Input voltage to ABS control valve pressure sensor (RL) signal circuit went 0.5 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS1, ABS3A and BPRL.
ness 1 Wiring harness between ABS3A (female) (16)
Resistance Max. 1 z
1 (Pressure sensor circuit) – BPRL (female) (1)
(Disconnection or defective Wiring harness between ABS3A (female) (20)
– BPRL (female) (3)
Resistance Max. 1 z
BPRL (female) (2)
Ground fault in wiring har- 2) Disconnect connectors ABS3A and BPRL.
2 ness 3) Connect T-adapter.
(Pressure sensor circuit) Wiring harness between ABS3A (female) (20),
BPRL (female) (3) – chassis ground
2) Disconnect connectors ABS3A and BPRL.
Hot short on wiring harness 4) Connect the connector.
3
(Pressure sensor circuit) 5) Turn on starting switch.
Possible causes Voltage Max. 4.7 V
BPRL (female) (3) – chassis ground
and standard value
2) Disconnect connectors ABS5A and S01F.
ness 2
4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) –
Resistance Max. 1 z
(Disconnection or defective S01F(female) (1)
contact)
Wiring harness between S01M (male) (2) –
Resistance Max. 1 z
S01F (female) (2)
2) Disconnect connectors ABS5A and BRC5A.
ness 3
5 (Retarder switch circuit) Wiring harness between ABS5A (female) (5) –
Resistance Max. 1 z
(Disconnection or defective BRC5A (F) (female) (4)
contact)
Wiring harness between BRC5A (M) (male) (4)
Resistance Max. 1 z
– BRC5A (F) (female) (4)
Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel
left: BPRL) restores the normal state.
(20) – ABS3A (female) (16)
20-1274 HD465-7, HD605-7

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HD465-7, HD605-7 20-1275

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[dk11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)

Trouble Accelerator sensor: Outside input signal range (KX)
E03 dk11KX ABS
Contents of trouble • Voltage of accelerator sensor signal circuit went 0.6 V or below or 4.7 V or above.
Related information

2) Disconnect connectors ABS3B and BRC3B.
ness
1 Wiring harness between ABS3B (female) (14)
– BRC3B (F) (female) (11)
contact)
Wiring harness between BRC3B (M) (male)
Resistance Max. 1 z
(11) – BRC3B (F) (female) (11)
2
ness Wiring harness between ABS3B (female) (14),
BRC3B (F) (female)(11), BRC3B (M) (male) Resistance Min. 1 Mz
Possible causes (11) – chassis ground
and standard value
3 Hot short on wiring harness 5) Turn on starting switch.
Wiring harness between ABS3B (female) (14),
BRC3B (F) (female)(11), BRC3B (M) (male) Voltage Max. 4.7 V
4 Defective accelerator sensor Replacing failed accelerator sensor restores the normal state.
2) Disconnect connectors ABS3B and BRC3A.
Across terminals between ABS3B (female)
(14) – ABS3A (female) (16)
20-1276 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1277

(12)
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION

(KA)

Trouble Wheel speed sensor front wheel right (FR): Disconnection (KA)
E03 DLF6KA ABS
Contents of trouble • Input of pulse signal to wheel speed sensor (FR) signal circuit is unavailable.
Related information

2) Disconnect connector WSFR.
1
sor (FR)
Wiring harness between WSFR (male) (1) – 1,150 –
Resistance
WSFR (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSFR.
ness
2 Wiring harness between ABS3A (female) (2) –
WSFR (female) (1)
contact)
Wiring harness between ABS3A (female) (14)
Resistance Max. 1 z
– WSFR (female) (2)
1) Turn off starting switch.Connect the connector.Connect the connec-
tor.
Possible causes
and standard value
in normal state Ground fault in wiring har-
3
ness Wiring harness between ABS3A (female) (2),
WSFR (female) (1) – chassis ground
Voltage Max. 5 V
2) Disconnect connectors ABS3A.
Across terminals between ABS3A (female) (2) 1,150 –
Resistance
– ABS3A (female) (14) 1,450 z
20-1278 HD465-7, HD605-7

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HD465-7, HD605-7 20-1279

(12)
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA)

Trouble Wheel speed sensor front wheel left (FL): Disconnection (KA)
E03 DLF7KA ABS
Contents of trouble • Input of pulse signal to wheel speed sensor (FL) signal circuit is unavailable.
Related information

2) Disconnect connector WSFL.
1
sor (FR)
Wiring harness between WSFL(male) (1) – 1,150 –
Resistance
WSFL (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSFL.
ness
2 Wiring harness between ABS3A (female) (3) –
WSFL (female) (1)
contact)
Resistance Max. 1 z
– WSFL (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSFL.
3 Wiring harness between ABS3A (female) (3),
ness Resistance Min. 1 Mz
WSFL (female) (1) – chassis ground
2) Disconnect connectors ABS3A and WSFL.
Voltage Max. 5 V
Across terminals between ABS3A (female) (3) 1,150 –
Resistance
– ABS3A (female) (14) 1,450 z
20-1280 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1281

(12)
[dLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA)

Trouble Wheel speed sensor rear wheel right (RR): Disconnection (KA)
E03 dLF8KA ABS
Contents of trouble • Input of pulse signal to wheel speed sensor (RR) signal circuit is unavailable.
Related information

2) Disconnect connector WSRR2.
1
sor (FR)
Wiring harness between WSRR2 (male) (1) – 1,150 –
Resistance
WSRR2 (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSRR2.
ness
2 Wiring harness between ABS3A (female) (12)
– WSRR2 (female) (1)
contact)
Resistance Max. 1 z
– WSRR2 (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSRR2.
WSRR2 (female) (1) – chassis ground
2) Disconnect connectors ABS3A and WSRR2.
Voltage Max. 5 V
Across terminals between ABS3A (female) 1,150 –
Resistance
(12) – ABS3A (female) (14) 1,450 z
20-1282 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1283

(12)
[dLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)

Trouble Wheel speed sensor rear wheel left (RL): Disconnection (KA)
E03 dLF9KA ABS
Contents of trouble • Input of pulse signal to wheel speed sensor (RL) signal circuit is unavailable.
Related information

2) Disconnect connector WSRL2.
1
sor (RL)
Wiring harness between WSRL2 (male) (1) – 1,150 –
Resistance
WSRL2 (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSRL2.
ness
2 Wiring harness between ABS3A (female) (13)
– WSRL2 (female) (1)
contact)
Resistance Max. 1 z
– WSRL2 (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSRL2.
WSRL2 (female) (1) – chassis ground
2) Disconnect connectors ABS3A and WSRL2.
Voltage Max. 5 V
Across terminals between ABS3A (female) 1,150 –
Resistance
(13) – ABS3A (female) (14) 1,450 z
20-1284 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1285

(12)
TROUBLESHOOTING [DWNDKZ]
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ)

Trouble ABS cut valve (F): Disconnection or short circuit (KZ)
E03 DWNDKZ ABS
• Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (F)
Contents of trouble circuit.
Action of controller • Stops ABS control (front wheels).
Problem that • ABS doesn't work (front wheels).
Related information

2) Disconnect connectors ABS1 and CVF.
ness
1 Wiring harness between ABS 1(female) (1) –
CVF (female) (1)
contact)
Wiring harness between CVF (female) (2) –
Resistance Max. 1 z
chassis ground
2
ness
and standard value CVF (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
CVF (female) (1) – chassis ground
4 Defective ABS cut valve (F): Replacing ABS cut valve (F) restores the normal state.
chassis ground
20-1286 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNDKZ]
HD465-7, HD605-7 20-1287

(12)
TROUBLESHOOTING [DWNDMA]
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)

Trouble ABS cut valve (F): Malfunction (MA)
E03 DWNDMA ABS
Contents of trouble • ABS cut valve (F) does not operate normally.
Action of controller • Stops ABS control (front wheel).
Related information

Defective ABS cut valve Replacing it with ABS cut valve pressure switch (R) restores the nor-
1
pressure switch (F) mal state.
2 Defective ABS cut valve (F) Replacing ABS cut valve (F) restores the normal state.
Possible causes Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSF.
and standard value 3 ness 3) Connect T-adapter.
contact) Wiring harness between ABS5A (female) (2) –
Resistance Max. 1 z
CVSF (female) (1)
2) Disconnect connectors ABS5A and CVSF.
4
ness
CVSF (female) (1) – chassis ground
20-1288 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNEKZ]
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ)

Trouble ABS cut valve (R): Disconnection or short circuit (KZ)
E03 DWNEKZ ABS
• Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (R)
Contents of trouble circuit.
Action of controller • Stops ABS control (rear wheels).
Problem that • ABS doesn't work (rear wheels).
Related information

2) Disconnect connectors ABS1 and RABS2.
ness
RABS2 (female) (1)
contact)
Wiring harness between RABS2 (female) (2) –
Resistance Max. 1 z
chassis ground
2
ness
and standard value RABS2 (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
RABS2 (female) (1) – chassis ground
4 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.
Resistance 10 – 30z
chassis ground
20-1290 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNEKZ]
HD465-7, HD605-7 20-1291

(12)
TROUBLESHOOTING [DWNEMA]
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)

Trouble ABS cut valve (R): Malfunction (MA)
E03 DWNEMA ABS
Contents of trouble • ABS cut valve (R) does not operate normally.
Related information

Defective ABS cut valve Replacing it with ABS cut valve pressure switch (F) restores the normal
1
pressure switch (R) state.
2 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.
Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSR.
Possible causes ness 3) Connect T-adapter.
in normal state Wiring harness between ABS5A (female) (3) –
CVSR (female) (1)
2) Disconnect connectors ABS5A and CVSR.
4
ness
Wiring harness between ABS5A (female) (3) ,
CVSR (female) (1) – chassis ground
20-1292 HD465-7, HD605-7

(12)
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)

Trouble ABS control valve front wheel right (FR): Disconnection (KA)
E03 DX21KA ABS
Contents of trouble • Current is not conducted as output is generated to ABS control valve (FR) circuit.
Related information

2) Disconnect connector ABS2 and ABSFR.
ness
ABSFR (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSFR (female) (2)
in normal state 2) Disconnect connector ABSFR.
Defective ABS control valve 3) Connect T-adapter.
2
(FR)
Across terminals between ABSFR (male) (1) –
ABSFR (male) (2)
Across terminals between ABS2 (female) (7) –
ABS2 (female) (17)
HD465-7, HD605-7 20-1293

(12)
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB)

Trouble ABS control valve front wheel right (FR): Short circuit (KB)
E03 DX21KB ABS
Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (FR) circuit.
Related information

chassis ground
chassis ground
Possible causes 1) Turn off starting switch.
and standard value 2) Disconnect connector ABSFR.
Defective ABS control valve
2 Across terminals between ABSFR (male) (1) –
(FR) Resistance 10 – 30 z
ABSFR (male) (2)
Wiring harness between ABSFR (male) (1) –
chassis ground
ABS2 (female) (17)
20-1294 HD465-7, HD605-7

(12)
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve front wheel right (FR):
Trouble
E03 DX21KY ABS Short-circuited with power supply (KY)
Contents of trouble • Current is conducted after output to ABS control valve (FR) circuit is turned off.
Related information

1 Hot short on wiring harness
and standard value Voltage Max. 1 V
ABSFR (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
ABSFR (female) (2) – chassis ground
ABS2 (female) (17)
HD465-7, HD605-7 20-1295

(12)
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA)

Trouble ABS control valve front wheel right (FR): Malfunction (MA)
E03 DX21MA ABS
Contents of trouble • ABS cut valve (FR) does not operate normally.
Related information

Possible causes
Defective ABS control valve Replacing it with ABS control valve pressure sensor (FL) restores the
and standard value 1
pressure sensor (FR) normal state.
in normal state
2 Replacing it with ABS control valve (FL) restores the normal state.
(FR)
20-1296 HD465-7, HD605-7

(12)
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)

Trouble ABS control valve front wheel left (FL): Disconnection (KA)
E03 DX22KA ABS
Contents of trouble • Current is not conducted as output is generated to ABS control valve (FL) circuit.
Related information

2) Disconnect connector ABS2 and ABSFL.
ness
ABSFL (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSFL (female) (2)
in normal state 2) Disconnect connector ABSFL.
2
(FL)
Across terminals between ABSFL (male) (1) –
ABSFL (male) (2)
ABS2 (female) (18)
HD465-7, HD605-7 20-1297

(12)
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)

Trouble ABS control valve front wheel left (FL): Short circuit (KB)
E03 DX22KB ABS
Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (FL) circuit.
Related information

1 Wiring harness between ABS2 (female) (8)
– chassis ground
chassis ground
and standard value 2) Disconnect connector ABSFL.
2 Across terminals between ABSFL (male) (1) –
(FL) Resistance 10 – 30 z
ABSFL (male) (2)
Wiring harness between ABSFL (male) (1) –
chassis ground
ABS2 (female) (18)
20-1298 HD465-7, HD605-7

(12)
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve front wheel left (FL): Short-circuit to power
Trouble
E03 DX22KY ABS supply
Contents of trouble • Current is conducted after output to ABS control valve (FL) circuit is turned off.
Related information

ABSFL (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
ABSFL (female) (2) – chassis ground
ABS2 (female) (18)
HD465-7, HD605-7 20-1299

(12)
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)

Trouble ABS control valve front wheel left (FL): Malfunction (MA)
E03 DX22MA ABS
Contents of trouble • ABS cut valve (FL) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FR) restores the
and standard value 1 normal state.
pressure sensor (FL)
in normal state
2 Replacing it with ABS control valve (FR) restores the normal state.
(FL)
20-1300 HD465-7, HD605-7

(12)
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)

Trouble ABS control valve rear wheel right (RR): Disconnection (KA)
E03 DX23KA ABS
Contents of trouble • Current is not conducted as output is generated to ABS control valve (RR) circuit.
Related information

2) Disconnect connector ABS2 and ABSRR.
ness
ABSRR (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSRR (female) (2)
in normal state 2) Disconnect connector ABSRR.
2
(RR)
Across terminals between ABSRR (male) (1) –
ABSRR (male) (2)
ABS2 (female) (19)
HD465-7, HD605-7 20-1301

(12)
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)

Trouble ABS control valve rear wheel right (RR): Short circuit (KB)
E03 DX23KB ABS
Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (RR) circuit.
Related information

chassis ground
chassis ground
and standard value 2) Disconnect connector ABSRR.
2 Across terminals between ABSRR (male) (1) –
(FR) Resistance 10 – 30 z
ABSRR (male) (2)
Wiring harness between ABSRR (male) (1) –
chassis ground
ABS2 (female) (19)
20-1302 HD465-7, HD605-7

(12)
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve rear wheel right (RR):
Trouble
E03 DX23KY ABS Short-circuited to power supply (KY)
Contents of trouble • Current is conducted after output to ABS control valve (RR) circuit is turned off.
Related information

ABSRR (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
ABSRR (female) (2) – chassis ground
ABS2 (female) (19)
HD465-7, HD605-7 20-1303

(12)
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)

Trouble ABS control valve rear wheel right (RR): Malfunction (MA)
E03 DX23MA ABS
Contents of trouble • ABS control valve (RR) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RL) restores the
pressure sensor (RR)
in normal state
2 Replacing it with ABS control valve (RL) restores the normal state.
(RR)
20-1304 HD465-7, HD605-7

(12)
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA)

Trouble ABS control valve rear wheel left (RL): Disconnection (KA)
E03 DX24KA ABS
Contents of trouble • Current is not conducted as output is generated to ABS control valve (RL) circuit.
Related information

2) Disconnect connector ABS2 and ABSRL.
ness
ABSRL (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSRL (female) (2)
in normal state 2) Disconnect connector ABSRL.
2
(RL)
Across terminals between ABSRL (male) (1) –
ABSRL (male) (2)
Across terminals between ABS2 (female) (10)
– ABS2 (female) (20)
HD465-7, HD605-7 20-1305

(12)
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB)

Trouble ABS control valve rear wheel left (RL): Short circuit (KB)
E03 DX24KB ABS
Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (RL) circuit.
Related information

chassis ground
chassis ground
and standard value 2) Disconnect connector ABSRL.
2 Across terminals between ABSRL (male) (1) –
(RL) Resistance 10 – 30 z
ABSRL (male) (2)
Wiring harness between ABSRL (male) (1) –
chassis ground
20-1306 HD465-7, HD605-7

(12)
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH
POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve rear wheel left (RL): Short-circuited with power
Trouble
E03 DX24KY ABS supply (KY)
Contents of trouble • Current is conducted after output to ABS control valve (RL) circuit is turned off.
Related information

ABSRL (female) (1) – chassis ground
in normal state
Voltage Max. 1 V
ABSRL (female) (2) – chassis ground
HD465-7, HD605-7 20-1307

(12)
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)

Trouble ABS control valve rear wheel left (RL): Malfunction
E03 DX24MA ABS
Contents of trouble • ABS control valve (RL) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RR) restores the
pressure sensor (RL)
in normal state
2 Replacing it with ABS control valve (FR) restores the normal state.
(RL)
20-1308 HD465-7, HD605-7

(12)
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)

Trouble ABS control valve (front wheel system): Malfunction (MA)
E03 DX25MA ABS
Contents of trouble • ABS control valve (FR) or ABS control valve (FL) does not operate normally.
Related information

(FR)
Possible causes Turn on ABS system check and locate from the failure code (DX21MA
and standard value Defective ABS control valve
and DX22MA) which of front wheel right or left is responsible for mal-
in normal state (FL)
1 function of ABS control valve.
After confirmation, inspect and repair the valve according to the failure
pressure sensor (FR) code.
pressure sensor (FL)
HD465-7, HD605-7 20-1309

(12)
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)

Trouble ABS control valve (rear wheel system): Malfunction (MA)
E03 DX26MA ABS
Contents of trouble • ABS control valve (RR) or ABS control valve (RL) does not operate normally.
Related information

(RR)
Possible causes Turn on ABS system check and locate from the failure code (DX23MA
and standard value Defective ABS control valve
and DX24MA) which of front wheel right or left is responsible for mal-
in normal state (RL)
1 function of ABS control valve.
After confirmation, inspect and repair the valve according to the failure
pressure sensor (RR) code.
pressure sensor (RL)
20-1310 HD465-7, HD605-7

(12)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................30- 3 Assembly.................................................. 30-73

PRECAUTIONS WHEN CARRYING FRONT WHEEL
OUT OPERATION .......................................30- 4 Removal and Installation.......................... 30-81
SPECIAL TOOL LIST................................. 30-5-1 REAR WHEEL
SKETCH OF SPECIAL TOOL.................... 30-5-4 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 FINAL DRIVE, REAR BRAKE AND
CYLINDER HEAD PARKING BRAKE
Removal....................................................30-17 Removal and Installation ......................... 30-97
Installation.................................................30-19 Disassembly............................................. 30-98
ENGINE Assembly................................................ 30-103
Removal....................................................30-22 FRONT SUSPENSION CYLINDER
Installation.................................................30-24 Removal ................................................. 30-109
TORQUE CONVERTER AND TRANSMISSION Installation .............................................. 30-110
Removal....................................................30-25 Disassembly (Standard cylinder).............30-111
Installation.................................................30-27 Assembly (Standard cylinder) ................ 30-112
TRANSMISSION AND TORQUE CONVERTER Disassembly
Separation and Coupling ..........................30-28 (Cylinder with buffer ring) .. 30-113-1
TORQUE CONVERTER Assembly (Cylinder with buffer ring) ... 30-113-2
Disassembly .............................................30-29 REAR SUSPENSION CYLINDER
Assembly ..................................................30-33 Removal and Installation........................ 30-114
TRANSMISSION Disassembly (Standard cylinder)............ 30-115
Disassembly .............................................30-39 Assembly (Standard cylinder) ................ 30-116
Assembly ..................................................30-52 Disassembly
DIFFERENTIAL (Cylinder with buffer ring) .. 30-117-1
Removal....................................................30-67 Assembly (Cylinder with buffer ring) ... 30-117-2
Installation.................................................30-68 RETARDER COOLING PUMP
Disassembly .............................................30-69 Removal and Installation........................ 30-118
HD465-7, HD605-7 30-1

(10)
STEERING, HOIST, AND HOIST CONTROL
PUMP
Removal and Installation ........................30-119
TORQUE CONVERTER, TRANSMISSION
AND RETARDER COOLING, AND BRAKE
PUMP
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

(10)
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

a Tools with part number 79 T- - can not be supplied (they are items to be locally manufactured).
a Necessity: t : .......Cannot be substituted, should always be installed (used)
q : .......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
a Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Nece New/ Ske-

Component Symbol Part No. Part Name -ssity Q’ty del tch
remo Nature of work, remarks
795-799-5410 Adapter t 1
Removal, installation of injec-
A tor assembly
795-799-5420 Remover t 1
795-621-1140 Push tool t 1

Installation of engine front
A2 795-902-1460 Bolt t 3 seal
01582-02218 Nut t 3
Engine assembly 795-621-1130 Push tool t 1

A3 Installation of engine rear seal
01050-32280 Bolt t 5
792-420-1110 Centering tool t 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 t 1

Disassembly, assembly of
1 790-901-2110 Bracket t 1
trque converter assembly
Torque convertor assem-
bly C 790-901-3011 Plate t 1
Removal, installation of PTO
2 790-101-1871 Nut wrench t 1
nut
Removal, installation of pump
3 792-103-5110 Wrench t 1
nut
• 792-420-1120 • Flange 2 Centring engine assembly and

Torque convertor
transmission assembly C4 torque converter, transmission
• 790-413-1120 • Color 1 assembly
• 01010-51230 • Bolt 8
Transmission assembly D1 799-301-1600 Oil leak tester t 1 Checking actuation of piston
790-501-5000 Unit repair stand t 1

Disassembly, assembly of dif-
1 790-901-5110 Bracket t 1
ferential assembly
Diffelential assembly H
790-901-3420 Plate t 1
2 790-425-1660 Wrench t 1 Adjust side bearing preload
30-5-1 HD465-7, HD605-7

(10)
Nece New/ Ske-

Removal, installation of bear-

3 790-102-1130 Power wrench t 1
ing cap bolt
Diffelential assembly H
Removal, installation of pin-
4 797-101-1171 Power wrench t 1
ion bearing lock nut
792T-422-1610 Spacer t 4 N Q
1 01010-61620 Bolt t 4
01643-31645 Washer t 4
Final drive and rear brake,

2 795-102-2102 Spring washer t 1 Removal, installation of spring
J
parking brake assembly
792-520-2110 Installer t 1 Removal, installation of floa-
3 tin seal
792-520-1600 Push tool t 1 (for small diameter)
791-585-1510 Installer t 1 Removal, installation of floa-

4 tin seal
792-530-1700 Push tool t 1 (for large diameter)
792-103-4102 Push tool t 1
792-625-1300 Push tool t 1 Press fitting of bushing

1 (for front)
790-101-5421 Grip t 1 (for rear)
Suspension cylinder
assembly
Q 01010-81240 Bolt t 1
792-610-1000 Suspension tool t 1

Adjusting of suspension cylin-
2 • 792-610-1100 • Pump assembly 1 der
• 792-610-1200 • Charging tool 1
Centering valve body and
1 790-452-1200 Pilot ring tool t 1
upper case
Steerin valve assembly T
2 790-452-1100 Tool installer set t 1 Installation of spacer
790-502-1003 Repair stand t 1

Disassembly and assembly
1
steering cylinder
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench t 1 Removal of cylinder head
3 790-302-1270 Socket t 1 Removal of piston nut
790-201-1702 Push tool KIT t 1
• 790-101-1771 • Push tool KIT t 1

Steering cylinder assembly U 4 Press fitting of bushing
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
790-201-1500 Push tool KIT t 1
• 790-101-1580 • Push tool KIT t 1

5 Press fitting of dust seal
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
HD465-7, HD605-7 30-5-2

(10)
Nece New/ Ske-

6 790-720-1000 Expander t 1
Steering cylinder assembly U 7 796-720-1650 Ring t 1 Removal of steerig cylinder
8 07281-01029 Clamp t 1
790-502-1003 Repair stand t 1

Disassembly, assembly of
1
hoist cylinder
790-101-1102 Hydraulic pump t 1
Removal, installation of cylin-
2 790-102-3802 Wrench t 1
der dead
3 790-720-1000 Expander t 1
4 796-720-1680 Ring t 1 Removal of piston ring
5 07281-01580 Clamp t 1
792-201-7310 Push tool t 1

Press fitting of bushing
790-101-5421 Grip t 1
(for cylinder )
01010-81240 Bolt t 1
6 790-201-1702 Push tool KIT t 1

Hoist cylinder assembly H
• 790-201-1851 • Push tool t 1
Press fitting of bushing
(for cylinder )
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
792-201-7410 Plate t 1
Press fitting of dust seal
790-101-5021 Grip t 1
(for cylinder )
01010-80816 Bolt t 1
7 790-201-1500 Push tool KIT t 1
• 790-201-1660 • Push tool t 1

Press fitting of dust seal
(for cylinder )
• 790-201-5021 • Grip t 1
• 01010-50816 • Bolt t 1
Dump body
assembly
V1 790-441-1320 Hook t 1 Lifting of dump body
799-703-1200 Service KIT tool t 1
799-703-1100 Vacuum pump t 1

Vacuum pump
Air conditioner assembly X 799-703-1111
(220V) t 1
Charging of air conditioner
Vacuum pump gas
799-703-1121
(240V) t 1
799-703-1401 Gas leak detector t 1
30-5-3 HD465-7, HD605-7

(11)
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOL
SKETCH OF SPECIAL TOOL
J1 Spacer
HD465-7, HD605-7 30-5-4

(10)
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 coolant.

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

(10)
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}
a When using 2 hose clamps to the same

place, set their clamps at an angle of 180° to
each other.
14. Lift off radiator assembly (17).
Radiator assembly: 310 kg • Refilling with coolant

Add coolant through the filler to the specified
level. Run the engine to circulate the coolant
through the system. Then, check the coolant
level again.
Radiator: 69
30-8 HD465-7, HD605-7

(10)
ENGINE AND TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY AND TRANSMISSION OIL COOLER

TION OF ENGINE 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)

4. Disconnect hoses (2) and (3). Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
5. Remove tubes (4) and (5). [Target: 279 Nm {28.5 kgm}]
6. Supporting the engine and torque converter and • Refilling with oil
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
etc., remove them. system. Then, check the oil level again.
Engine and torque converter and trans- Engine oil pan:
mission oil cooler assembly: 140 kg
57 (EO10-CD or EO30-CD)
Hydraulic tank: 122 (EO10-CD)
HD465-7, HD605-7 30-9

(10)
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.
a 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 t 1
A2 795-902-1460 Bolt t 3
01582-02218 Nut t 3
REMOVAL
1. Remove the radiator assembly. For details, see
REMOVAL AND 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

(10)
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT

INSTALLATION
TION OF OUTPUT SHAFT
ASSEMBLY • Carry out installation in the reverse order to
removal.
a For application of ENS grease to each part, see
REMOVAL
DISASSEMBLY AND ASSEMBLY.
the wheels with blocks. Mounting bolt: Adhesive (LT-2)
Mounting bolt:
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.
a 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

(3)

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 for reassembly.
2) Remove body assembly (7) and rubber
pieces (8) from body outer (9).
a 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

(10)
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)
a 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.
Bore 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).
a When installing large and small rubber
pieces (8), check their locations.
a 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}
a When installing the body outer, body inner,
and flange, match them to their marks.
HD465-7, HD605-7 30-13

(10)
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

(3)
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 t 1
A3
01050-32280 Bolt t 5
REMOVAL
1. Remove the output shaft assembly. For details,
see REMOVAL AND INSTALLATION OF OUT-
PUT SHAFT ASSEMBLY. 2. Install flywheel (1).
a 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. a Check each mounting bolt head for punch
Take care. marks. If there are 5 punch marks, replace
Flywheel: 45 kg the bolt.
a 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
a 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

(10)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
a 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

(3)
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 t 1
A
795-799-5420 Remover t 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 coolant.
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).
14. Remove turbocharger and exhaust manifold
6. Disconnect each wiring connector and ground
wire and move wiring harness (4). assembly (16).
Turbocharger and exhaust manifold
7. Remove air intake connectors (6) and (7).
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

(10)
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
a After tightening the bolts, make a punch a

a Check that there is not foreign matter on the mark a on the main bolt (Do not make the
fitting face of the cylinder head and in the cyl- punch mark if the bolts are new).
inder.
a When fitting the gasket, check that the grom-
met is not removed.
a Check each mounting bolt head for punch
marks. If there are 3 punch marks, replace
the bolt.
a Tighten the cylinder head mounting bolts in
the following order.
Mounting bolt:
Molybdenum disulfide grease (LM-P)
Cylinder head mounting bolts
((1) – (7)):
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 coolant
cylinder head with paint, Add coolant through the filler to the specified
then retighten the bolts 90° level. Run the engine to circulate the coolant
– 120°. through the system. Then, check the coolant
Mounting bolts ((8), (9)) level again.
93.2 – 103 Nm {9.5 – 10.5 kgm}
Radiator: 69
HD465-7, HD605-7 30-21

(10)
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 AND INSTALLATION OF RADIATOR
ASSEMBLY.
3. Remove the radiator cross bar.
4. Remove washer tank (4).
30-22 HD465-7, HD605-7

(10)
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
14. Sling the engine assembly temporarily.
15. Remove engine mounting bolts (23) and (24)

and pull out engine assembly (25) forward to
remove it.
a When removing the engine assembly, check
that the all wires and pipes are disconnected
and take care that the engine assembly will
not interfere with the chassis.
Engine assembly: 2,750 kg
HD465-7, HD605-7 30-23

(10)
INSTALLATION • Refilling with coolant

Add coolant through the coolant filler to the spec-
• Carry out installation in the reverse order to ified level. Run the engine to circulate the cool-
removal. ant through the system. Then, check the coolant
level again.
a When tightening the bolts, check that the key Radiator: 69

way of the spider cap is fitted to the key way
of the mating yoke.
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a 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.
Engine mount mounting bolt (Both front

and rear):
343 – 426.3 Nm {35.0 – 43.5 kgm}
a 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}
30-24 HD465-7, HD605-7

(10)
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

(3)
9. Disconnect hoses (12), (13), and (14) and tubes 11. Remove mounting bolts (17) and (18) of the front
(15) and (16) from the left underside of the trans- and rear mounts, then remove torque converter
mission. and transmission assembly (19).
a When removing the torque converter and
transmission assembly, check that the all
wires and pipes are disconnected and take
care that the assembly will not interfere with
the chassis.
a Check the thickness and quantity of the
shims set in the rear mount.
• Standard thickness of shims: 2 mm
• Thickness of each shim: 0.5 mm (1 type)
Torque converter and transmission
assembly: 1,600 kg
10. Sling the torque converter and transmission

assembly temporarily.
30-26 HD465-7, HD605-7

(10)
INSTALLATION a If the transmission mount bracket was

removed from the chassis, tighten its mount-
• Carry out installation in the reverse order to ing bolts to the following torque.
removal.
Mounting bolt:
450 – 608 Nm {50 – 62 kgm}
,
a When tightening the bolts, check that the key • Refilling with oil
way of the spider cap is fitted to the key way Add oil through the oil filler to the specified level.
of the mating yoke. Run the engine to circulate the oil through the
system. Then, check the oil level again.
Mounting bolt: Adhesive (LT-2) Transmission case:

Mounting bolt: 190 (EO30-CD or EO10W-CD)
157 – 198 Nm {16.0 – 20.1 kgm}

Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a 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.
HD465-7, HD605-7 30-27

(10)
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
790-501-5000 Unit repair stand ■ 1
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 11. Disassembly of pump, stator shaft, and rear

Pull up and remove stator assembly (44). housing assembly
1) Remove snap ring (51) and inner race (52).
2) Using tool C3, remove nuts (53).
10. Disassembly of stator assembly

1) Remove stator (45).
3) Remove the pump, stator shaft, and rear

housing assembly from tool C1.
4) Remove the mounting bolts and push out

and remove stator shaft (54).
a At this time, inner race (55) comes off.
2) Remove bushings (47) and (48) and free

wheel (49) from outer race (46).
a Take care not to lose balls (50).
5) Remove seal ring (56), inner race (57), and

sleeve (58) from stator shaft (54).
30-32 HD465-7, HD605-7

(10)
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).
a 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).

a 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).
a Fit sleeve (58) by expansion fit.
HD465-7, HD605-7 30-33

(3)
5) Install stator shaft assembly (54) to rear 8) Using tool C3, tighten nuts (53).
housing (63). a Drop about 6 CC of engine oil (EO10-CD
Mounting bolt: Adhesive (LT-2) or EO30-CD) over the bearing and rotate
the bearing 10 turns.
Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm} Threads of nut: Adhesive (LT-2)
Nut: 441.3 – 490.3 Nm {45 – 50 kgm}
9) Install inner race (52) and snap ring (51).
a Install the inner race with the wider end
face up.
6) Install the stator shaft and rear housing

assembly to tool C1.
7) Install pump assembly (64) and inner race
(55) to stator shaft (54).
a Inner race (55) is an assembly. Check
that the serial No. and match symbol (A 2. Assembly of stator assembly
or B) on its end face are the same as 1) Install free wheel (49) to outer race (46).
those on the mating bearing. a Install the free wheel with its arrow mark
end on the input side. Check the revolv-
ing direction of the outer race, seeing it
from the input side.
Clockwise: Free rotation
Counterclockwise: Locked
Sliding surface:
Engine oil (EO10-CD or EO30-CD)
2) Install balls (50) to outer race (46), then

install bushings (48) and (47) by expansion
fit.
Sliding surface:
30-34 HD465-7, HD605-7

(10)
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
or EO30-CD) over the bearing and rotate
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
or EO30-CD) over the bearing and rotate
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.
a Install the nuts with the chamfered side
down.
a Tighten the nuts fully after installing the
PTO case assembly. After this, follow the
procedure: 7-3 (making coupling serve as
a stopper).
Threads of nut: Adhesive (LT-2)
8. Install elbows (5) and tube (6).

a 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 Elbow: 16.7 – 29.4 Nm {1.7 – 3.0 kgm}
1) Sling PTO case assembly (10) and fit the O-
ring. Using guide bolt [10], install the PTO 10. Install torque converter intermediate pressure
case assembly. sensor (3).
a When installing the PTO case assembly, Threads of sensor:
match the match marks. Gasket sealant (LG-5)
Mounting bolt: Sensor: 9.8 – 19.6 Nm {1 – 2 kgm}
98.1 – 122.6 Nm {10 – 12.5 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).
a Use the coupling as a stopper.
Nut:
392.4 – 441.5 Nm {40 – 45 kgm}
30-38 HD465-7, HD605-7

(10)
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 t 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.
a 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

(3)
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.)
a The locations of the clutch ports are shown
below.
• No. 1 clutch port: A
• No. 2 clutch port: B
• No. 3 clutch port: C
a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
• Standard stroke of clutch No. 1 piston:
4.2 mm
2) Remove cover (17) from the oil pan, then

remove spring (18) and magnet assembly
(19).
6. No. 1 clutch plates

1) Using sling bolts, remove No. 1 clutch plates
(24).
a 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).
30-40 HD465-7, HD605-7

(10)
2) Remove bearing (25) from No. 1 clutch plates. 2) Remove seal rings (100) and (101) from pis-
ton (32).
7. No. 1 clutch spring and guide

Remove spring (26) and guide (27). 10. Input shaft and No. 1 ring gear assembly
1) Sling the input shaft and remove the input
8. Discs, plates, and springs shaft and No. 1 ring gear assembly (33).
Remove discs (28), plates (29), and spring (30).
2) Pull up and remove No. 1 ring gear (34).

9. No. 1 clutch drum and piston 3) Remove seal rings (206) and (207) from the
1) Using hanging bolts, remove clutch No. drum input shaft.
(31) and piston (32) together, then separate
them from each other.
HD465-7, HD605-7 30-41

(10)
4) Remove inner race (35) from No. 1 ring gear 7) Remove snap ring (39), then remove bearing
(34). (40) from input shaft (41).
5) Remove snap ring (36) and press down and 11. No. 2 clutch assembly
remove gear (37). Lift off 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).
30-42 HD465-7, HD605-7

(10)
2) Remove mounting bolts, cover (44), and pis- 5) Remove snap ring (53) and ring gear (54).
ton (45).
6) Remove discs (55), plates (56), and spring

3) Remove seal ring (46) from piston (45). (57).
7) Using sling bolts, remove drum (58).
4) Housing assembly
i) Remove seal rings (47) and (48). 8) Remove plates (59) from carrier (60).
ii) Remove snap ring (49), bushing (50),
and ball (205).
aTake care not to lose ball (205).
iii) Remove inner race (51) and bearing
(52).
HD465-7, HD605-7 30-43

(10)
9) Carrier assembly 13. Transmission case

i) Remove shaft (61). 1) Remove cage assembly mounting bolts (69)
a Take care not to lose ball (62). and lift off transmission case (70) vertically.
ii) Remove planetary gears (63), thrust
washer (64), and bearing (65).
2) Remove the following parts from the trans-

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.
iii) Remove seal ring (66), inner race (67), and

bearing (68) from carrier (60).
14. Check of operation of piston

Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
Standard strokes of pistons
Piston No. Stroke (mm)
4 4.8
5 5.8
6 5.0
7 5.0
30-44 HD465-7, HD605-7

(10)
17. No. 3 clutch ring gear

1) Remove No. 3 clutch ring gear (80).
2) Remove inner race (81) and seal ring (82)
from the ring gear.
15. No. 3 clutch housing assembly

Remove the housing mounting bolts and No. 3
clutch housing assembly (75).
a For disassembly, see Step 12, DISASSEM-
BLY OF NO. 2 CLUTCH ASSEMBLY, 1) - 4).
(No. 3 clutch assembly has the same struc-
ture as No. 2 clutch assembly.)
18. Tie bolts

Remove tie bolts (83).
16. No. 3 clutch drum, discs, and plates 19. No. 4 clutch plates and sun gear
1) Using hanging bolts, remove No. 3 clutch drum 1) Remove plates (84).
(76), discs, plates, and spring together. 2) Remove snap ring (85) and sun gear (86).
2) Remove discs (77), plates (78), and spring
(79).
HD465-7, HD605-7 30-45

(10)
3) Remove seal ring (200) from No. 4 sun gear 21. No. 4 housing, piston, and ring gear
(86). 1) Using hanging bolts, remove No. 4 housing
(91), piston (92), and ring gear (93) together.
a If the dowel pin is hard to remove and it
may cuff the housing, take care not to
cause damage.
20. No. 4 clutch discs, plates, and springs

Remove discs (87), plates (88) and (101), and
springs (89) and (90).
a Distinguish plates (88) and (101) from each
other. 2) Remove seal rings (93) and (94) from No. 4
a Since springs (90) of a clutch line have a part housing (91) and piston (92).
No. different from those of another clutch
line, store them for each clutch line.

Remove discs (95), plates (96), and springs (97)
and (98).
a Since springs (97) of a clutch line have a part
No. different from those of another clutch
line, store them for each clutch line.
30-46 HD465-7, HD605-7

(10)
4) Remove sleeve (203) for tie bolt (83) from

No. 5 housing and check the direction of the
sleeve (slit A).
23. No. 5 housing, piston, ring gear, and guide

pins
1) Using sling bolts, remove No. 5 housing (99),
piston (102), and ring gear (103) together. 24. No. 6 clutch discs, plates, and springs
a If the dowel pin is hard to remove and it Remove discs (108), 4 plates (109) and (110),
may cuff the housing, take care not to and springs (111) and (112).
cause damage. a Since springs (111) of a clutch line have a
2) Remove guide pins (202). part No. different from those of another
clutch line, store them for each clutch line.
a Distinguish plates (109) and (110) from each
other.
3) Remove seal rings (106) and (107) from No.

5 housing (99) and piston (102).
HD465-7, HD605-7 30-47

(10)
25. No. 4 and No. 5 carriers assembly 4) Drive out shaft (117) from the ball side and
Using hanging bolts, remove No. 4 and No. 5 remove No. 5 planetary gears (119), bearing
carriers assembly (201). (120), collar (121), and thrust washer (122).
a At this time, 4 of 8 No. 5 planetary gears
come off.
26. Disassembly of No. 4 and No. 5 carriers assem-

bly
1) Remove No. 5 sun gear (113). 5) Drive out shaft (123) toward No. 4 carrier and
remove ball (124).
a 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).
a Take care not to lose the ball.
30-48 HD465-7, HD605-7

(10)
27. No. 6 and No. 7 housings, pistons, and springs

1) Using sling bolts, remove No. 6 and No. 7
housings (131) and pistons (132) and (133).
a If the dowel pin is hard to remove and it
may cuff the housing, take care not to
cause damage.
29. No. 6 and No. 7 carriers assembly

Using sling bolts, sling the shaft and remove No.
6 and No. 7 carriers assembly (142).
2) Remove seal rings (134), (135), and (136)

from No. 6 and No. 7 housings and pistons
(132) and (133).
30. Disassembly of No. 6 and No. 7 carriers assem-

bly
1) Remove collar (143).
2) Remove inner race (144) and snap ring (145)
from collar (143).
Remove discs (138), plates (139), and springs
(140) and (141).
a Since springs (141) of a clutch line have a
part No. different from those of another
clutch line, store them for each clutch line.
HD465-7, HD605-7 30-49

(10)
3) Tighten forcing screws [1] to remove plates a Hit both shafts evenly to drive out the
(146). above parts gradually.
4) Remove seal ring (147) and bearing (148) 9) Remove seal ring (170) from collar (159).
from the plates. 10) Remove planetary gear No. 7 (162), bearing
(163), and thrust washer (164).
11) Remove snap ring (165), collar (166), and
ball (167).
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.
3) Remove bearing (174) from the cage.
8) After removing No. 6 planetary gear, drive

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).
30-50 HD465-7, HD605-7

(10)
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). a Check that the snap ring is fitted to the
10) Install snap ring (151). collar groove.
a 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
a Securely press fit the bearing to the gear to the bearing.
specified 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

(10)
9. Assembly of No. 4 and No. 5 carriers assembly

1) Install bearing (125) 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.
a Check that the shaft, bearing, thrust
washers, and carrier are aligned and
take care that the bearing and thrust
washers will not be damaged.
a 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
a 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.
a 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
a Check that the external teeth are deformed.
meshed with the internal teeth and the a 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.
a 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.
a 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

(10)

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)

Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
2) Install No. 3 clutch ring gear (80). a 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
a If the pistons do not move smoothly, apply

engine oil to them.
21. No. 3 clutch housing assembly

a For sassembly, see Step 24, assembly of No.
2 clutch assembly, 5) – 8). (No. 3 clutch
assembly has the same structure as No. 2
clutch assembly.)
a The plates, discs, and springs are each 1
less than those of No. 2 clutch assembly.
a 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.
a Press fit the bearings until they are
stopped by collars (73).
30-60 HD465-7, HD605-7

(10)
★ 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}

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
★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
• 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
790-501-5000 Unit repair stand ■ 1
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
a Push in the torque pin and fix it with the bolt
1. Remove the front wheel assembly. For details, securely.
see REMOVAL AND INSTALLATION OF a Adjust the clearance between the pin and
FRONT 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}
a Pin fixing bolt (2) and pull out pin (1) to a a For precautions for installing the pin fixing
degree that you can remove the pads. bolt, see DISASSEMBLY, ASSEMBLY OF
FRONT BRAKE CALIPERS ASSEMBLY.
a 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

(10)
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 AND INSTALLATION OF 785 – 980 Nm {80.1 – 100 kgm}
FRONT WHEEL ASSEMBLY.
a 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).

a Sling the calipers assembly, adjusting it with
a lever block, etc.
Calipers assembly: 75 kg
HD465-7, HD605-7 30-85

(10)

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).

a 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).

a 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}
a 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.
a 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

(4)
a Be sure to install torque pin (4), (5) which is

shorter than torque pin (5) to the plate side.
a Assemble the other pistons similarly.
5. Install the front brake calipers assembly. For

details, see REMOVAL AND INSTALLATION OF
FRONT BRAKE CALIPERS.
a 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

(10)
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
a 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

(10)
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).
a Degrease the sealing side of wheel hub
A and periphery of the seal.
a 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
a 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 a 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

(3)
a 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}
a 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} a 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].
a 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.
a Measure at 2 places and obtain the
average.
a Combine the shims so that their
quantity will be minimum.
a 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

(10)
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}
• Refilling with oil
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- a 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 t 4 N
J 1 01011-61620 Bolt t 4
01643-31645 Washer t 4
REMOVAL
6. Remove retainer (7) and shim (8).
1. Remove the dump body assembly. For details, a Before removing the retainer completely,
see REMOVAL AND 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- a 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 AND 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, method of releas-
ing parking brake in an emergency.
5. Using tool J1, fix outer gear (5) and wheel hub
(6).
a Be sure to install tool J1 to protect the float-
7. Remove ring gear assembly (9).
ing seal before removing the retainer.
Ring gear assembly: 100 kg
HD465-7, HD605-7 30-93

(10)
8. When disassembling the ring gear assembly, a 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).
a 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

(3)
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.
a 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].
a Measure at 2 places and obtain the aver-
age.
3) Remove retainer (7) and measure its thick-
ness b.
a 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).
a 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

(3)
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 AND INSTAL-
LATION OF FINAL DRIVE AND REAR BRAKE
ASSEMBLY.
a 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.
a 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

(10)
DISASSEMBLY AND ASSEM- 3. Parking brake assembly

1) Check that the parking brake is released.
BLY OF FINAL DRIVE, REAR (See TESTING AND ADJUSTING, Method of
BRAKE, AND PARKING releasing parking brake in an emergency.)
BRAKE ASSEMBLY 2) Remove parking brake assembly (1).
a 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 t 4 N Q
1 01011-61620 Bolt t 4
01643-31645 Washer t 4
2 795-102-2102 Spring washer t 1
J
792-520-2110 Installer t 1
3
792-530-1600 Push tool t 1
791-585-1510 Installer t 1
4
791-530-1700 Push tool t 1
• For the sketch of tool J1, see SKETCH OF SPE- 4. Disassembly of parking brake assembly
CIAL TOOL.
Since the installing load on the internal
spring is large, disassemble the assembly
DISASSEMBLY carefully according to the following proce-
Remove the internal parts (piston, damper, dure.
disc, plate, floating seal, etc.) carefully so that 1) Gradually loosen and remove parking brake
they will not be damaged by impacts, fall, etc. releasing bolts A (10 pieces).
a Loosen all releasing bolts A evenly so
1. Place the final drive, rear brake, and parking that the internal brake piston will not
brake assembly with the parking brake side up. slant.
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

(10)
2) Turn over the parking brake assembly. 6) Remove seal rings (8) and (9) from cylinder
3) Gradually and evenly loosen and remove 13 (7).
cylinder mounting bolts (4).
7) Remove 30 springs (10) from cylinder (2).

4) Remove cylinder (7). a There are 22 double springs and 8 single
a Make match marks on cylinder (7) and springs.
piston assembly (3) for reference for a Make distinction marks at locations of the
installation. single springs (8 places) with paint for
reference for installation.
5) Remove piston assembly (3).

a 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

(10)
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 AND 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 AND INSTALLATION OF 9. Remove 4 bolts (8).
FRONT 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 q.
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

(10)
INSTALLATION
removal.
k 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
k Before operating the steering system after

them.
finishing installation, be sure to refill the

front suspension cylinder with nitrogen gas
and adjust it. For details, see TESTING
AND ADJUSTING, Testing and adjusting
front suspension cylinder.
30-110 HD465-7, HD605-7

(10)
DISASSEMBLY AND ASSEM- 2. Remove feed valve (1) and valve (2).
BLY OF FRONT SUSPENSION 3. Removal of cylinder rod assembly.

CYLINDER ASSEMBLY 1) Remove flange mounting bolts (3) and air
(Standard cylinder) bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
retainer (7), and flange (8) together.
Special tools
New/Remodel
4. Disassembly of flange
Symbol
Necessity
Part No. Part name
1) Remove plate (6), retainer (7), and flange (8)
Sketch
from rod assembly (5).
Q'ty
2) Remove dust seal (9) and bushing (10) from
792-103-4102 Push tool t 1 retainer (7).
1 790-101-5421 Grip t 1 3) Remove U-packing (11) and bushing (12)
from flange (8).
01010-81240 Bolt t 1
Q
5. Remove wear ring (13) from cylinder rod (5).
2 792-610-1100 • Pump assembly 1
792-610-1200 • Charging tool 1
DISASSEMBLY
• Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
HD465-7, HD605-7 30-111

(10)
ASSEMBLY 2) Press fit bushing (10) to retainer (7) and

(See the figure for disassembly, too.) install dust seal (9).
a 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)
a When installing the U-packing, check a 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.
a Apply rust-preventive oil to part A indi- 2) Using a block, erect the cylinder.
cated with 2-dot chain lines on the a 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.
a If the rod assembly is inserted too deep,
the oil spouts out. Stop it to a position
where the oil does not spout out.
a 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

(3)
5) Install air bleeding valve (4).

Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install valve (2) and feed valve (1).

Oil level valve and air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
a The dust cover consists of 2 pieces. Reduce
the clearance between them to 0.5 mm or
less.
HD465-7, HD605-7 30-113

(10)
DISASSEMBLY AND ASSEM- 2. Remove feed valve (1) and valve (2).
BLY OF FRONT SUSPENSION 3. Removal of cylinder rod assembly.

CYLINDER ASSEMBLY 1) Remove flange mounting bolts (3) and air
(Cylinder with buffer ring) bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
retainer (7), and flange (8) together.
Special tools
4. Disassembly of flange
New/Remodel
Symbol
Necessity
Part No. Part name
1) Remove plate (6), retainer (7), and flange (8)
Sketch
from rod assembly (5).
Q'ty
2) Remove dust seal (9) and bushing (10) from
792-103-4102 Push tool t 1 retainer (7).
1 790-101-5421 Grip t 1
3) Remove U-packing (11), buffer ring (14) and
bushing (12) from flange (8).
01010-81240 Bolt t 1
Q
792-610-1000 Suspension tool t 1 5. Remove wear ring (13) from cylinder rod (5).
2 792-610-1100 • Pump assembly 1
792-610-1200 • Charging tool 1
DISASSEMBLY
• Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
30-113-1 HD465-7, HD605-7

(10)
ASSEMBLY k Buffer ring (14) is made of 2 parts. When

(See the figure for disassembly, too.) installing it, set the round corner of part [2]
(Black) inside of part [1] (Blue).
1. Installation of wear ring • The side indicated by the arrow is the pres-
sure side.
2 Outside of wear ring:
Install wear ring (13) to cylinder rod (5).
2. Assembly of flange
1) Using tool Q1, press fit bushing (12) to flange
(8) and install U-packing (11) and buffer ring
2 Inside of bushing:
(14).

a When installing the U-packing, check
that there are 4 projections on the top of
the inside lip.
2) Press fit bushing (10) to retainer (7) and

install dust seal (9).
a When press fitting the bushing, take care
2 Periphery of seal:
not to deform it.
Adhesive (LT-2)
3. Assembly of cylinder rod assembly

the cylinder rod.
2 Mating faces of flange and retainer:
a Apply rust-preventive oil to part A indi-
cated with 2-dot chain lines on the a Apply the gasket sealant evenly to
periphery of the U-packing (NISSEKI hatched part B and apply it thinly to U-
P1300 or equivalent). packing C so that it will not be projected.
2) Using a block, erect the cylinder.

a Fill the cylinder with engine oil.
5 Cylinder: Approx.
16.5 l (EO10-CD)
HD465-7, HD605-7 30-113-2

(8)

to the cylinder.
a If the rod assembly is inserted too deep,
the oil spouts out. Stop it to a position
where the oil does not spout out.
a 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.

the cylinder with bolts (3).
3 Mounting bolt:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
5) Install air bleeding valve (4).

3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install valve (2) and feed valve (1).

3 Oil level valve and air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
a The dust cover consists of 2 pieces. Reduce
the clearance between them to 0.5 mm or
less.
30-113-3 HD465-7, HD605-7

(10)
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

"

BLY OF REAR SUSPENSION
CYLINDER ASSEMBLY
(Standard cylinder)
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-625-1300 Push tool t 1
1 790-101-5421 Grip t 1
01010-81240 Bolt t 1
Q 5. Flange and retainer
1) Remove retainer (6) and flange (8) from cyl-
2 792-610-1100 • Pump assembly 1
inder rod assembly (7).
792-610-1200 • Charging tool 1 2) Remove U-packing (10), backup ring, and O-
ring (11) from flange (8).
DISASSEMBLY 3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
1. Guard retainer (6).
Sling the cylinder assembly and loosen clamp
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.
3. Feed valve and valve

Remove cover (3), feed valve (4), and 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

(10)
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
(8).
1) Using a block, erect cylinder (9).
2) Install U-packing (10) to flange (8).
to cylinder (9).
cated with 2-dot chain lines on the
3) Install flange (8) and retainer (6) to cylinder
rod assembly (7).
3) Install backup ring and O-ring (11) to flange Mating faces of flange and retainer:
(8). Gasket sealant (LG-6)
a 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

(3)
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 level (5) and feed
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

(10)

BLY OF REAR SUSPENSION
CYLINDER ASSEMBLY
(Cylinder with buffer ring)
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-625-1300 Push tool t 1
1 790-101-5421 Grip t 1
01010-81240 Bolt t 1
Q 5. Flange and retainer
1) Remove retainer (6) and flange (8) from cyl-
2 792-610-1100 • Pump assembly 1
inder rod assembly (7).
792-610-1200 • Charging tool 1 2) Remove U-packing (10), buffer ring (17),
backup ring and O-ring (11) from flange (8).
DISASSEMBLY 3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
1. Guard retainer (6).
Sling the cylinder assembly and loosen clamp
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.
3. Feed valve and valve

Remove cover (3), feed valve (4), and valve (5).
6. Wear ring
Remove wear ring (15) from rod (16).

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.
30-117-1 HD465-7, HD605-7

(10)
ASSEMBLY
1. Wear ring
Install wear ring (15) to rod (16).
3. Retainer
1) Using tool Q1, install bushing (14) to retainer
(6).
2. Flange 2) Install seal (13) to retainer (6).
2 Periphery of seal: Adhesive (LT-2)
1) Using tool Q1, install bushing (12) to flange
(8).
2) Install U-packing (10) and buffer ring (17) to
flange (8).
cated with 2-dot chain lines on the
k Buffer ring (17) is made of 2 parts. When

installing it, set the round corner of part [2]

(Black) inside of part [1] (Blue).
3) Install backup ring and O-ring (11) to flange
(8).

1) Using a block, erect cylinder (9).
to cylinder (9).
3) Install flange (8) and retainer (6) to cylinder
rod assembly (7).
2 Mating faces of flange and retainer:
HD465-7, HD605-7 30-117-2

(8)
a Apply the gasket sealant evenly to 5. Feed valve and valve

hatched part B and apply it thinly to U- 1) Set the cylinder assembly upside down.
packing C so that it will not be projected. (Set the rod down.)
2) Sling the cylinder so that dimension D on the
rod side will be as follows.
When buffer ring is not installed: 140 ± 3 mm
When buffer ring is installed: 124 ± 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 level (5) and feed
valve (4).
3 Air intake valve and oil level:
39.2 – 49.0 Nm {4 – 5 kgm}
5) Install cover (3).
4) Install retainer (6) and flange (8) together to

cylinder (9) with the mounting bolts.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
6. Guard
1) Install guard (2) and secure it with clamp (1).
3 Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}
30-117-3 HD465-7, HD605-7

(10)
DISASSEMBLY AND ASSEMBLY RETARDER COOLING PUMP

TION OF RETARDER COOL-
ING PUMP ASSEMBLY
REMOVAL
pin.
1. Disconnect tubes (1) and (2) and hose (3).

a Prepare a pan to receive oil from the joints.
2. Remove retarder cooling pump assembly (4).

Retarder cooling pump assembly: 30 kg
INSTALLATION
removal.

Transmission case:
190 (EO30-CD or EO10W-CD)
30-118 HD465-7, HD605-7

(10)
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:
Raise the dump body and lock it with the safety Hydraulic tank: 122 (EO10-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

(10)
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.

Transmission case:
30-120 HD465-7, HD605-7

(10)
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,
★ 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).
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 a 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).
a 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.
a 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 – 7.6 kgm}
not fall even if they are set down. a Tighten the mounting bolts in the diagonal
a 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 – 7.6 kgm}
30-130 HD465-7, HD605-7

(10)
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
790-101-1102 Hydraulic pump ■ 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
790-101-1102 Hydraulic pump ■ 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 ASSEM- Dump body assembly
HD465-7: 10,750 kg
BLY HD605-7: 13.450 kg
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
V1 790-441-1320 Hook t 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.

a Check the thickness, quantity, and location of
the shims.
HD465-7, HD605-7 30-141

(10)
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

!
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. a There are 2 position adjustment washers
a Use a flat-head screwdriver, etc. to (16) installed to each bolt between the
remove the cap. armrest and seatback. Take care not to
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.
a 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.
a 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

(10)
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).
a 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).
a 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

(4)
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. Skide rails
each rail. 1) Put height adjustment washers (31) between
slide rails (28) and suspension, and then set
slide 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 slide rails (28) to the front end and install
each rail, and then remove rails (28). 1 lock washer (30) and 1 hexagon socket
head bolt (29) to each slide rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
3) Set slide rails (28) to the rear end and install
1 lock washer (30) and 1 hexagon socket
head bolt (29) to each slide rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HD465-7, HD605-7 30-149

(10)
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}
a 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

(4)
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

• The procedure for assembling right-hand arm- a 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.
a 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

(4)
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).
a Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6).

Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
30-152 HD465-7, HD605-7

(10)
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
Electrical circuit diagram (A1 size) (1/2)................................................90-23
Electrical circuit diagram (A1 size) (2/2)................................................90-25
Electrical system diagram related to ABS controller ......................... 90-26-1
Electrical circuit diagram related to ABS ........................................... 90-26-3
Connectors table (A1 size) ....................................................................90-27
Arrangement drawing (A1 size).............................................................90-29
HD465-7, HD605-7 90-1

(12)
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HD465-7, HD605-7

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
*1 EMERGENCY STEERING FLOW SWITCH

HD465-7 Serial No.: 7001 – 7151
HD605-7 Serial No.: 7001 – 7059
*2 EMERGENCY STEERING OIL PRESSURE SWITCH
HD465-7, HD605-7 90-3

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BRAKE HYDRAULIC CIRCUIT DIAGRAM
*1 HD465-7 Serial No.: 7266 and up

HD465-7, HD605-7 90-5

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ELECTRICAL CIRCUIT DIAGRAM (1/6)
HD465-7, HD605-7 90-7

HD465-7, HD605-7 90-9

HD465-7, HD605-7 90-11

HD465-7, HD605-7 90-13

HD465-7, HD605-7 90-15

HD465-7, HD605-7 90-17

ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
HD465-7, HD605-7 90-19

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ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
HD465-7, HD605-7 90-21

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ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (1/2) HD465, 605-7 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (1/2) HD465, 605-7
HD465-7, HD605-7 90-23

ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (2/2) HD465, 605-7 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (2/2) HD465, 605-7
HD465-7, HD605-7 90-25

ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER
HD465-7, HD605-7
HD465-7, HD605-7 90-26-1

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ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS
HD465-7, HD605-7
HD465-7, HD605-7 90-26-3

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CONNECTORS TABLE (A1 SIZE) HD465, 605-7
CONNECTORS TABLE (A1 SIZE)
ABS control related
Connector Number of Connector Number of Connector Number of Connector Number of Connector Number of Type of Number
No. Type of connector pin Location Address No. Type of connector pin Location Address No. Type of connector pin Location Address No. Type of connector pin Location Address No. Type of connector pin Location Address Connector No. Location Address
connector of pin
01 Terminal 1 Battery relay (B) B9 BZ2 M 2 Buzzer R1 E16B Terminal 1 Grounding AH9 OP5 M 1 Machine monitor setting connector M8, O9 SLG Terminal 1 Grounding J2 ABS M 6 ABS system switch BK7
02 Terminal 1 Battery relay (M) B9 CAB1 DT-T (Gray) 8 Intermediate connector Q9 E17A DT-T 2 Diode AJ8 OP6 M 1 Machine monitor setting connector N8, O8 SLL M 1 Side lamp (If equipped) J2 ABS1 MIC 17 ABS controller BR3
03 Terminal 1 Battery relay (B) B9 CAB2 DT-T (Black) 8 Intermediate connector Q9 E17B DT-T 2 Diode AJ8 OP7 M 1 Machine monitor setting connector N8, O8 SLR M 1 Side lamp (If equipped) C7 ABS1 DT-T 6 Joint connector BF9
04 Terminal 1 Battery relay (M) B9 CAN DT 3 CAN connector AJ6 E2B DT 2 Diode AE5 OPS DT-T 2 Seat heater T2 S-NET MS3102A 14S 5 S-NET monitor T1 ABS2 MIC 21 ABS controller BR3
05 Terminal 1 Emergency steering relay (B) A8 CAN1 DT-T 3 VHMS CAN connector T9 ECM A DRC26 40 Engine controller AG5 PL01 M 2 Left head lamp (LOW) D1 SP1 PACKARD 2 Engine speed sensor (Master) AJ8 ABS2 DT-T 8 Joint connector BD2
06 Terminal 1 Emergency steering relay (M) A8 CAN2 DT-T 3 Resistor Q1 ECM B DRC26 40 Engine controller AG9 PL02 M 2 Left head lamp (HIGH) D2 SP2 PACKARD 2 Engine speed sensor (Backup) AJ8 ABS3 DT-T 6 Joint connector BE2
07 Terminal 1 Emergency steering relay (B) A8 CG1 One-pin connector 1 Cigarette lighter M5 EG4 DT-T (Brown) 12 Intermediate connector V9 PL03 One-pin connector 1 Clearance lamp E1 SPA1 DT-T 4 Spare connector 1 ABS3A 40 20 ABS controller BR8
08 Terminal 1 Emergency steering relay (M) A9 CG2 — 1 Cigarette lighter M5 ENG DT-T (Gray) 8 Intermediate connector AJ7 PL04 One-pin connector 1 Clearance lamp E1 SPA2 DT-T 12 Spare connector 2 ABS3B 40 16 ABS controller BQ9
11 Terminal 1 Battery relay (E) B8 CH1 S 8 Machine monitor mode selector switch 1 M1 ER Terminal 1 Grounding C9, C8, E9, G9 PL05 One-pin connector 1 Turn signal E1 SPA3 DT-T 6 Spare connector 3 F1 ABS4 40 12 ABS controller BR8
12 Terminal 1 Battery relay (BR) B8 CH2 S 8 Machine monitor mode selector switch 2 M1 ER1 Terminal 1 Grounding P1 PL06 One-pin connector 1 Fog lamp (If equipped) D1 SPL YAZAKI 2 Speaker (Left) G9 ABS4 DT-T 6 Joint connector BE2
12 KES0 2 Washer tank motor — CJA DT-T 6 Joint connector D8 ER2 Terminal 1 Grounding X7 PL07 Terminal 1 Grounding D2 SPR YAZAKI 2 Speaker (Right) F9 ABS5 DT 6 Joint connector BF3
13 Terminal 1 Battery relay (E) C8 CJB DT-T (Black) 8 Joint connector B7 ER3 Terminal 1 Grounding O2 PM1 MIC 21 VHMS wiring harness T9 SR2 X 3 Steering speed sensor P1 ABS5A 40 20 ABS controller BR8
14 Terminal 1 Battery relay (BR) C8 CJB DT-T 6 Joint connector E8 FBC M 6 Front brake cutting switch N3 PM3 DT-T 3 Pitch angle sensor X7 SR3 X 2 Pitch angle sensor X7 ABS6 DT-T 6 Joint connector BG8
15 Terminal 1 Emergency steering relay (E) A8 CJC DT-T 6 Joint connector D8 FL01 DT-T 2 Radiator coolant level sensor B3 PM4 S (Natural color) 16 VHMS wiring harnes T9 SUFL DT-T 3 Suspension oil pressure sensor(FL) (If equipped) H1 ABS7 DT-T 6 Joint connector BH8
16 Terminal 1 Emergency steering relay (BR) A7 CJD DT 6 Joint connector D8 FL04 YAZAKI 2 Washer motor B3 PM5 MIC 13 Payload meter controller T9 SUFR DT-T 3 Suspension oil pressure sensor(FR) (If equipped) B7 ABS8 DT-T 6 Joint connector BE9
17 Terminal 1 Emergency steering relay (E) B7 CJE2 DT-T 6 Joint connector AI9 FL05 DT-T 2 Air conditioner dual switch B2 PM6 AMP040 12 Payload meter controller U9 SURL DT-T 3 Suspension oil pressure sensor(RL) (If equipped) L8 ABSFL DT-T 2 ABS valve AX9
18 Terminal 1 Emergency steering relay (BR) B7 CJE3 DT-T (Black) 8 Joint connector A12 FLB — 1 Flasher R1 PM7 AMP 9 VHMS wiring harnes SURR DT-T 3 Suspension oil pressure sensor(RR) (If equipped) J9 ABSFR DT-T 2 ABS valve AX9
20 — 1 Circuit breaker A9 CJH1 DT-T (Black) 8 Joint connector — FLL — 1 Flasher R1 PM7 AMP 9 Payload meter controller N7 T01 DT-T 2 Fuel level gauge sensor G9 ABSRL DT-T 2 ABS valve BH7
21 — 1 Circuit breaker A9 CJH2 DT-T 6 Joint connector — FLTP PACKARD 2 Fuel temperature sensor AF9 PM8 BENDIX 5 Connector N7 T02 DT-T 6 Retarder oil temperature sensor H9 ABSRR DT-T 2 ABS valve BF9
22 — 1 Circuit breaker A9 CJK DT 6 Joint connector B8 FOG M 6 Fog lamp switch (If equipped) N1 PM9 MIC 21 VHMS wiring harness T9 T05 Terminal 1 Grounding I9 BPFL DT-T 3 Brake oil pressure AW9
23 — 1 Circuit breaker B9 CJL DT-T 6 Joint connector L7 FR01 DT-T 2 Air cleaner clogging sensor B7 PM10 S (Natural color) 16 VHMS wiring harnes T9 T1 Terminal 1 Grounding AC9 BPFR DT-T 3 Brake oil pressure AX9
1939 HD30 9 Connector for connecting J1939 device — CJN DT (Black) 8 Joint connector J3 FS2 One-pin connector 2 Spare terminal X6 PM11 MIC 21 Intermediate connector V9 TEST One-pin connector 1 TEST switch V8 BPRL DT-T 3 Brake oil pressure BH8
A One-pin connector 1 Lamp (Optional for payload meter) — CJP DT-T 6 Joint connector I9 FS3 One-pin connector 2 Spare terminal X7 PMLA DT-T (Gray) 12 Intermediate connector H9 TG One-pin connector 1 Tachograph S9 BPRR DT-T 3 Brake oil pressure BG9
A One-pin connector 1 Lamp (Optional for payload meter) — CJP1 DT-T 6 Joint connector H9 FS4 One-pin connector 2 Spare terminal X7 PMPR PACKARD 3 Fuel pump pressure sensor AF5 TG2 One-pin connector 1 Tachograph S9 BRC3B 40 16 Retarder controller BO9
A1 M 1 Emergency reset connector X6 CJP2 DT-T 6 Joint connector I9 FS5 One-pin connector 2 Spare terminal X7 PMRA DT-T 6 Intermediate connector D8 TIMG PACKARD 3 Timing rail actuator AG9 BRC4 40 12 Retarder controller BP9
A2 M 1 Emergency reset connector V8 CJPR DT-T 6 Joint connector C8 FS8 One-pin connector 2 Spare terminal X6 POW HD30 21 Intermediate connector AJ7 TM2 HD30 21 Intermediate connector AD8 BRC5A 40 20 Retarder controller BQ9
AAPR PACKARD 3 Air pressure sensor AH5 CJS DT-T 6 Joint connector L7 FSO- Terminal 1 Fuel shut-off valve - AE7 PR01 M 2 Right head lamp (LOW) A5 TM3 HD30 31 Intermediate connector AD8 CHK Yazaki 6 System check switch BL8
ABS M 6 ABS system switch O2 CJSL DT-T 6 Joint connector I9 FSO+ Terminal 1 Fuel shut-off valve + AE7 PR02 M 2 Right head lamp (HIGH) A4 TMF DT-T 2 Transmission oil filter sensor J3 CVF DT-T 2 ABS cut solenoid AZ8
AC1 One-pin connector 1 Air conditioner wiring harness M3 CJT DT (Black) 8 Joint connector L8 FUA Terminal — Fuse box (30 A) C9 PR03 One-pin connector 1 Clearance lamp A5 TPR PACKARD 3 Timing rail pressure sensor AI6 CVR DT-T 2 ABS cut solenoid BG9
ACBM YAZAKI 2 Air conditioner blower motor T2 CJT1 DT-T (Black) 8 Joint connector L7 FUB Terminal — Fuse box (120 A x 2) C9 PR04 One-pin connector 1 Clearance lamp A5 TR - 6 Brake lamp timer X7 CVSF DT-T 3 ABS cut switch AY8
ACCF DT-T 3 ACC oil pressure sensor (Front) L4 CJT2 DT-T 6 Joint connector H9 G One-pin connector 1 Lamp (Payload meter) (If equipped) — PR05 One-pin connector 1 Turn signal A5 VHM DT-T (Black) 8 Intermediate connector C2 CVSR DT-T 3 ABS cut switch BH8
ACCR DT-T 3 ACC oil pressure sensor (Rear) K3 CJW DT-T 6 Joint connector G One-pin connector 1 Lamp (Payload meter) (If equipped) — PR06 One-pin connector 1 Fog lamp (Optional) A6 WFM M 6 Front wiper motor Q1 DA1 DT-T 2 Diode BE9
ACM1 AMP 5 Temperature regulation servomotor V3 CK1 YAZAKI 6 Bulb breakage check switch M2 G21 Terminal 1 Grounding S1 PR07 Terminal 1 Grounding A4 WFR Relay 6 Front wiper relay R1 DPC2B AMP070 12 Machine monitor P1
ACM2 AMP 5 Air outlet mode selection servomotor M6 CLTP PACKARD 2 Coolant temperature sensor AE8 GND Terminal 1 Engine block GND AF8 PSOL DT-T 2 Parking brake solenoid L6 WPS DT-T (Black) 12 Wiper switch Q8 FOGF M 6 Fog lamp switch BM1
ACM3 AMP 5 Recirculated/Fresh air selection servomotor W3 CM DT-T (Green) 8 Lighting switch, passing switch, turn switch Q8 H01 DT-T 2 Steering flow switch K3 PSW DT-T 2 Parking brake switch K3 WSRL DT-T 2 Wheel speed sensor (RL) K1 FOGM M 6 Fog lamp switch BK8
ACP1 AMP 16 Air conditioner control panel O7 CN3 DT-T 2 Input shaft speed sensor AC9 H10 One-pin connector 1 Heater unit M4 PUMP PACKARD 3 Fuel pump actuator AF5 WSRR DT-T 2 Wheel speed sensor (RR) K1 J06 HD30 31 Intermediate connector BD1
ACP2 AMP 12 Air conditioner control panel O7 CN4 DT-T 2 Intermediate shaft speed sensor AC9 H20 One-pin connector 1 Heater unit M4 PWL One-pin connector 1 Power window motor (Left) I2 VHMS controller related JABS DT-T 12 Intermediate connector BA9
ACPS SUMITOMO 2 Air conditioner pressure switch U2 CN5 DT-T 2 Output shaft speed sensor AD7 HAZ M 6 Hazard switch O7 PWM M 6 Power mode switch M4 CAN1 DT-T 3 VHMS intermediate connector AU2 RABS KES1 6 ABS cut relay BS7
ACR1 Relay 4 Blower main relay W3 CN6 DT-T 2 Solenoid for transmission 1st clutch AB9 HEAT DT 2 Heater control AJ7 PWR One-pin connector 1 Power window motor (Right) C7 DLSW Terminal 1 Ground level download box AO1 RABS2 KES1 6 ABS cut valve relay BS7
ACR2 Relay 4 Blower Hi relay W4 CN7 DT-T 2 Fill switch for transmission 1st clutch AB9 HEPC DT-T 2 Hoist EPC valve L5 R One-pin connector 1 Lamp (Payload meter) (If equipped) EG4 DT-T 12 VHMS intermediate connector AV3 S01F DT-T 3 Service brake switch BC1
ACR3 Relay 4 Blower M2 relay W4 CN8 DT-T 2 Solenoid for transmission 2nd clutch AB9 HES Terminal 1 Grounding — R One-pin connector 1 Lamp (Payload meter) (If equipped) GDL DT-T 12 Ground level download box intermediate connector AP4 S01M DT-T 3 Service brake switch AZ1
ACR4 Relay 4 Blower M1 relay W4 CN9 DT-T 2 Fill switch for transmission 2nd clutch AA9 HN One-pin connector 1 Horn switch Q8 R01 Relay 5 Engine starting relay AB4 GR1 Terminal 1 Ground level download box AP2 S02F DT-T 3 Secondary brake switch BC9
ACR5 Relay 4 Compressor clutch relay W4 CN10 DT-T 2 Solenoid for transmission R clutch AA9 HN1A — 1 Horn valve A4 R02 Relay 5 Transmission Neutral relay AB3 GR2 Terminal 1 Ground level download box AP2 S02M DT-T 3 Secondary brake switch BC9
ACRE AMP 4 Air conditioner blower resistor U2 CN11 DT-T 2 Fill switch for transmission R clutch AA9 HN1B — 1 Horn valve A4 R03 Relay 5 Parking brake relay AB3 HM-12 DT-T 3 Blow-by sensor AM6 WSFL DT-T 2 Wheel speed sensor BC1
ACTH YAZAKI 2 Thermistor U3 CN12 DT-T 2 Solenoid for transmission 3rd clutch AA9 HN2A — 1 Horn valve A4 R04 Relay 5 Brake lamp relay (RL) AB3 HM-21A DT 2 Exhaust temperature sensor AN8 WSFR DT-T 2 Wheel speed sensor AY7
AISS M 6 AISS switch M3 CN13 DT-T 2 Fill switch for transmission 3rd clutch AA9 HN2B — 1 Horn valve A3 R05 Relay 6 Backup lamp, buzzer relay AB2 HM-21B DT 2 Exhaust temperature sensor AN7 WSRL2 DT-T 2 Wheel speed sensor BG9
ARC M 3 ARSC set switch P8 CN14 DT-T 2 Solenoid for transmission 4th clutch AA9 HSL DT-T 4 Intermediate connector V3 R06 Relay 6 Fog lamp relay AC4 HM-22A DT 2 Exhaust temperature sensor - amp intermediate connector AR8 WSRR2 DT-T 2 Wheel speed sensor BF9
ARSC M 6 ARSC system switch N3 CN15 DT-T 2 Fill switch for transmission 4th clutch Z9 HSL DT-T 4 Hoist lever potentiometer V3 R07 Relay 5 AISS relay AB4 HM-22B DT 2 Exhaust temperature sensor - amp intermediate connector AQ7
AS1 SWP 6 Acceleration sensor N2 CN16 DT-T 2 Solenoid for transmission L clutch Z8 HSOL DT-T 3 Hoist selector valve L5 R08 Relay 5 Brake lamp relay (CTR) AB3 HM-23A DT-T 3 VHMS - exhaust temperature amp intermediate connector AR8
AS2 X 3 Acceleration sensor O2 CN17 DT-T 2 Fill switch for transmission L clutch Z8 HTA DT-T (Gray) 8 Intermediate connector L6 R09 Relay 5 Brake lamp timer relay AB2 HM-23B DT-T 3 VHMS - exhaust temperature amp intermediate connector AQ7
ASR M 6 ASR system switch O2 CN18 DT-T 2 Solenoid for transmission H clutch Y8 HTB DT-T (Black) 8 Intermediate connector L6 R10 Relay 5 PLM GDL relay AC4 HM-31 DT 2 Engine oil temperature sensor AN1
ASR1 DT-T-T 2 Steering angle sensor C2 CN19 DT-T 2 Fill switch for transmission H clutch Y7 IMPR PACKARD 3 Intake air pressure sensor AF8 R11 Relay 5 Horn relay AC4 HM-35 DT 2 Ambient temperature sensor AM1
ASR2 DT-T-T 2 Shut off valve L2 CN20 DT-T 2 Solenoid for torque converter lockup clutch Z8 IMTP PACKARD 2 Intake air temperature sensor AF8 R14 Relay 5 Brake cutting relay AB4 HM50 DT-T 3 Short connector AU2
ASR3 DT-T-T 2 ASR valve (R) K3 CN21 DT-T 2 Fill switch for torque converter lockup clutch Z8 J01 HD30 9 Intermediate connector I2 R15 Relay 5 Transmission cutting relay A2 HM55 DT-T 3 Short connector AQ6
ASR4 DT-T-T 2 ASR valve (L) L3 CN22 DT-T 3 Torque converter intermediate pressure sensor Z5 J02 HD30 31 Intermediate connector I2 R16 Relay 6 Hazard relay 1 AB1 HM81 M 8 VHMS - Orbcomm controller intermediate connector AT2
ASR5 DT-T 2 ASR oil pressure switch (R) K3 CN23 DT-T 2 Torque converter oil temperature sensor AA5 J03 HD30 31 Intermediate connector I2 R17 Relay 5 Hazard relay 2 AC1 HM-2130 YAZAKI 2 Resistor AQ2
ASR6 DT-T 2 ASR oil pressure switch (L) L2 CN24 DT-T 2 Transmission valve oil temperature sensor AC5 J04 HD30 31 Intermediate connector H1, AN6 R19 Relay 5 Parking brake safety relay AC4 HM-2140 YAZAKI 2 Resistor AR2
ASR7 DT-T 2 ASR oil ptessure switch (Main) K1 CNS1 DT-T (Brown) 12 Intermediate connector (Power window switch) J05 HD30 31 Intermediate connector H1, AN6 R21 Relay 6 Side lamp relay AC4 HM-CN1 AMP070 20 VHMS controller AS8
ASS DT-T 2 Air suspension seat T2 CNS2 DT-T (Green) 12 Intermediate connector (Gear shift lever) J07 HD30 14 Intermediate connector H1 R22 Relay 5 Rotary lamp relay AD3 HM-CN2A AMP070 18 VHMS controller AT7
ATC1 MIC 17 Transmission controller Z1 CNS3 DT-T (Black) 12 Intermediate connector (Parking brake switch) J08 HD30 31 Intermediate connector G1 R25 YAZAKI 11 Power window relay AC1 HM-CN2B AMP070 12 VHMS controller AU7
ATC2 MIC 21 Transmission controller Z1 COM One-pin connector 1 Air conditioner wiring harness M3 J09 HD30 31 Intermediate connector G1 R29 Relay 5 Head lamp Hi relay AD2 HM-CN3A AMP070 18 VHMS controller AT8
ATC3A AMP040 20 Transmission controller Z4 D01 DT-T 2 Diode W8 J10 HD30 31 Intermediate connector G1 R30 Relay 5 Head lamp Lo relay AD1 HM-CN3B AMP070 12 VHMS controller AS8
ATC3B AMP040 16 Transmission controller Z4 D02 DT-T 2 Diode W8 JC01 DT 6 Joint connector AI6 R32 Relay 5 Dust indicator relay AC1 HM-CN4A AMP070 14 VHMS controller AU7
ATC4 AMP040 12 Transmission controller AA4 D03 DT-T 2 Diode W8 JC02 DT (Black) 8 Joint connector AI5 R33 Relay 6 Parking brake manual switch R9 HM-CN4B AMP070 10 VHMS controller AT8
ATC5A AMP040 20 Transmission controller AA1 D04 DT-T 2 Diode M6 JC03 DT (Black) 8 Joint connector AH5 R34 YAZAKI 7 Power window switch (Left) S1 LM1 Terminal 1 Ground level download box lamp terminal AP3
ATC5B AMP040 16 Transmission controller AA4 D05 DT-T 2 Diode V8 JC04 DT (Black) 8 Joint connector AG5 R35 YAZAKI 7 Power window switch (Right) S9 LM2 Terminal 1 Ground level download box lamp terminal AP3
ATC6 X 4 Software rewriting connector (Transmission controller) W4 D07 DT-T 2 Diode P2 JC11 DT 6 Joint connector AG5 R37 Relay 5 Auto preheater relay AD3 ORB-A AMP070 14 Orbcomm controller AS2
B01 DT-T 6 Intermediate connector K9 D08 DT-T 2 Diode W8 JC12 DT 6 Joint connector AH5 R40 Relay 6 Payload meter relay (If equipped) AD2 ORB-B AMP070 10 Orbcomm controller AS2
B02 DT-T 6 Intermediate connector K8 DL DT-T (Black) 12 Intermediate connector X6 JC13 DT (Black) 8 Joint connector AI5 R43 Relay 5 Green outside pilot lamp relay of payload meter AD2 PDL MS 5 Ground level download box PLM connector AP2
B03 DT-T 6 Winker lamp, stop lamp, tail lamp J9 DPC1 AMP070 20 Machine monitor P8 JC14 DT (Black) 8 Joint connector AI6 R44 Relay 5 Yellow outside pilot lamp relay of payload meter AD2 PLM MS 5 PLM II download connector AQ6
B04 Terminal 1 Backup lamp J9 DPC2A AMP070 18 Machine monitor P1 JC15 DT 6 Joint connector AI6 R45 Relay 5 Red outside pilot lamp relay of payload meter AD1 PM1 MIC 21 PLM II intermediate connector AV3
B05 Terminal 1 Backup alarm buzzer J9 DPC2B AMP070 12 Machine monitor P1 JCA DT-T (Black) 8 Joint connector X5 RAD YAZAKI 9 AM/FM radio O2 PM4 S 16 PLM II intermediate connector AU7
B06 Terminal 1 Backup alarm buzzer J9 DPC3A AMP070 18 Machine monitor P8 JCB DT-T (Black) 8 Joint connector X5 RAIL PACKARD 3 Fuel rail actuator AF5 PM11 MIC 21 VHMS intermediate connector AV6
B07 DT-T 3 Body position sensor K9 DPC4 AMP070 12 Machine monitor Q1 JCC DT-T (Black) 8 Joint connector X5 RDC YAZAKI 9 Cassette stereo O2 SPA1 DT-T 4 Ambient temperature sensor intermediate connector AO6
B1 One-pin connector 1 Lamp (Payload meter) (If equipped) — DPC6 AMP040 8 Machine monitor O7 JCD DT-T (Black) 8 Joint connector X4 RE1 YAZAKI 2 Resistor S9 SPA2 DT-T 12 Ground level download box intermediate connector AO6
B1 One-pin connector 1 Lamp (Payload meter) (If equipped) — DPC7 X 4 Software rewriting connector (Machine monitor) N3 JCE DT-T (Black) 8 Joint connector X4 RE2 YAZAKI 2 Resistor S9 VDL MS 5 Ground level download box VHMS connector AP3
B10 Terminal 1 Grounding K8 DSL — 1 Door switch (Left) F1 JCF DT-T (Black) 8 Joint connector S9 RE3 YAZAKI 2 Resistor P8 VHM DT-T 8 Blow-by, oil temperature sensor intermediate connector AM6
B11 Terminal 1 Grounding L8 DSR — 1 Door switch (Right) T2 JCG DT-T (Black) 8 Joint connector V3 RE4 YAZAKI 2 Resistor P8 VHMS MS 5 VHMS download connector AT2
B2 One-pin connector 1 Lamp (Payload meter) (If equipped) — DT7 DT-T 12 Intermediate connector T2 JT1 DT-T 6 Joint connector AD7 RESW DT-T 2 Retarder switch L4 WAKE Terminal 1 Ground level download box AP2
B2 One-pin connector 1 Lamp (Payload meter) (If equipped) — DT8 DT-T 4 Intermediate connector J2 JT2 DT-T 6 Joint connector AD7 RETV DT-T 2 Retarder valve L4
B3 One-pin connector 1 Lamp (Payload meter) (If equipped) — E Terminal 1 Emergency steering motor LINK DT 6 Data link crossover AJ6 RL YAZAKI 2 Room lamp E9
B3 One-pin connector 1 Lamp (Payload meter) (If equipped) — E01 Terminal 1 Alternator AE7 LKO DT-T 2 Intermediate connector U3 RL2 One-pin connector 1 Room lamp 2 G9
BCOM One-pin connector 1 Beacon lamp T9 E02A DT-T 2 Starting motor AH1 LKO DT-T 2 Lever kick-out solenoid V3 RP DT-T 6 Intermediate connector A6
BK DT-T (Gray) 8 Intermediate connector F9 E02B DT-T 2 Starting motor AH1 LP DT (Gray) 12 Intermediate connector I2 RPR PACKARD 3 Fuel rail pressure sensor AI6
BL One-pin connector 1 Intermediate connector C7 E03 DT-T 2 Engine speed sensor AF1 LS M 3 Rheostat M1 RT2 Terminal 1 Emergency steering timer M4
BLS M 6 Rotary lamp switch (If equipped) N1 E04 DT-T 2 Oil level switch (If equipped) AH5 M Terminal 1 Emergency steering motor RT6 Terminal 1 Emergency steering timer M5
BR One-pin connector 1 Air conditioner wiring harness M4 E05 Terminal 1 Oil filter switch C2 MON1 One-pin connector 1 Rear view monitor (If equipped) N7 RT7 Terminal 1 Emergency steering timer M5
BRC1 MIC 17 Retarder controller Y2 E06 Terminal 1 Alternator AE6, AF1 MON2 One-pin connector 1 Rear view monitor (If equipped) N7 RT8 Terminal 1 Emergency steering timer M4
BRC2 MIC 21 Retarder controller Y2 E07 DT-T 2 Compressor AF8 MON3 One-pin connector 1 Rear view monitor (If equipped) O7 RTL DT-T 6 Retarder potentiometer P8
BRC3A AMP040 20 Retarder controller Y4 E08 DT-T 2 Diode AG9 MS11 M 1 Model selection connector (Transmission controller) U9 S01 DT-T 2 Service brake switch B7
BRC3B AMP040 16 Retarder controller Y4 E09 Terminal 1 Alternator AE6 MS12 M 1 Model selection connector (Transmission controller) U9 S02 DT-T 2 Secondary brake switch E9
BRC4 AMP040 12 Retarder controller Z4 E10 Terminal 1 Grounding AG9 MS21 M 1 Model selection connector (Transmission controller) U9 S03 DT-T 2 Front brake cutting solenoid (If equipped) E9
BRC5A AMP040 20 Retarder controller Y1 E11A Terminal 1 Heater relay AJ9 MS22 M 1 Model selection connector (Transmission controller) U9 S04 DT-T 2 Auto suspension solenoid 1 (If equipped) F9
BRC5B AMP040 16 Retarder controller Y2 E11B Terminal 1 Ribbon heater AH9 MS31 M 1 Model selection connector (Transmission controller) U9 S05 DT-T 2 Auto suspension solenoid 2 (If equipped) F9
BRC6 X 4 Software rewriting connector (Retarder controller) S9 E12A Terminal 1 Heater relay AJ9 MS32 M 1 Model selection connector (Transmission controller) V3 SBS DT-T 2 Seat belt switch U2
BT DT 6 Intermediate connector C9 E12B Terminal 1 Ribbon heater AG9 OLPR PACKARD 3 Engine oil pressure sensor AE5 SDE M 6 Side lamp switch (If equipped) N2
BT1 — — Fuse box X5 E13A DTHD (#4) 1 Intermediate connector AG1 OP1 M 1 Machine monitor setting connector M8, N9 SF1 DT-T (Green) 12 Shift lever R9
BT2 — — Fuse box X7 E13B DTHD (#4) 1 Intermediate connector AG1 OP2 M 1 Machine monitor setting connector M8, N9 SF2 DT-T 2 Shift lever Q9
BT3 — — Fuse box X6 E15 Terminal 1 Grounding AI2 OP3 M 1 Machine monitor setting connector M8, O9 SIG HD30 31 Intermediate connector AJ7
BT4 — — Fuse box X6 E16A Terminal 1 Grounding AI9 OP4 M 1 Machine monitor setting connector M8, O9 SLG Terminal 1 Grounding C8
HD465-7, HD605-7 90-27

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ARRANGEMENT DRAWING (A1 SIZE) HD465, 605-7
ARRANGEMENT DRAWING (A1 SIZE)
HD465-7, HD605-7 90-29

(12)

HD465 7 Shop Manual SN 7001 Up PDF

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SEBM027612

MACHINE MODEL SERIAL NUMBER

HD465-7 7001 and up

• HD465-7, HD605-7 mount 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

00-2-6 HD465-7, HD605-7

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

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! 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

k Before carrying out the following work, release Type 1

k 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, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE