Spesifikasi HD465-7R PDF

SEN02283-01
DUMP TRUCK
HD465 -7R
HD605 -7R
HD465- 15001
SERIAL NUMBERS and up
HD605- 16001
SEN02285-01
DUMP TRUCK 1SHOP MANUAL
HD465-7R
HD605-7R
Machine model Serial number

HD465-7R 15001 and up
HD605-7R 16001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
HD465-7R, HD605-7R 1
SEN02285-01 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02283-01
00 Index and foreword SEN02284-01

Index SEN02285-01 q
Foreword and general information SEN02286-00
01 Specification SEN02287-00
Specification and technical data SEN02289-00
10 Structure, function and maintenance standard SEN02290-00

Engine and cooling system SEN02291-00
Power train system, Part 1 SEN02292-00
Steering system SEN02294-00
Brake system SEN02295-00
Undercarriage and frame SEN02296-00
Hydraulic system SEN02297-00
Cab and its attachments SEN02298-00
Electrical system, Part 1 SEN02299-00
20 Standard value table SEN02308-00

Standard service value table SEN02527-00 Q
30 Testing and adjusting SEN02309-00

Testing and adjusting, Part 1 SEN02528-00 Q
40 Troubleshooting SEN02310-00
Failure code table and fuse locations SEN02717-00 Q
General information on troubleshooting SEN02718-00 Q
2 HD465-7R, HD605-7R
Troubleshooting by failure code, Part 1 SEN02533-00 Q

Troubleshooting of electrical system (E-mode) SEN02542-00 Q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02543-00 Q
Troubleshooting of engine (S-mode) SEN02544-00 Q
90 Diagrams and drawings SEN02312-01

Hydraulic circuit diagram SEN02313-00
Electrical circuit diagram SEN02314-01 q
HD465-7R, HD605-7R 3
Table of contents 1
00 Index and foreword
Index SEN02285-01
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02286-00

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02289-00
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Fuel, coolant and lubricants ........................................................................................................ 10
10 Structure, function and maintenance standard

Engine and cooling system SEN02291-00
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler........... 2
Fuel system ................................................................................................................................. 4
Brake oil cooler............................................................................................................................ 5
Output shaft................................................................................................................................. 6
Power train skeleton.................................................................................................................... 2
Drive shaft ................................................................................................................................... 4
Torque converter and transmission hydraulic piping ................................................................... 6
Brake cooling oil control valve (BCV) .......................................................................................... 8
Torque converter ......................................................................................................................... 10
Torque converter valve ................................................................................................................ 17
Transmission ............................................................................................................................... 19
Transmission control valve .......................................................................................................... 35
ECMV .......................................................................................................................................... 36
Axle ............................................................................................................................................. 2
Differential ................................................................................................................................... 4
Final drive.................................................................................................................................... 5
Wheels ........................................................................................................................................ 6
Steering system SEN02294-00
Steering column........................................................................................................................... 2
Steering linkage........................................................................................................................... 3
Brake system SEN02295-00
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Secondary brake valve................................................................................................................ 7
Relay valve.................................................................................................................................. 8
Front brake off valve.................................................................................................................... 9
4 HD465-7R, HD605-7R
Accumulator charge valve........................................................................................................... 10

Accumulator ................................................................................................................................ 14
Slack adjuster.............................................................................................................................. 15
Brake........................................................................................................................................... 17
Parking brake solenoid valve ...................................................................................................... 21
Undercarriage and frame SEN02296-00
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 4
Rear axle support........................................................................................................................ 10
Hydraulic system SEN02297-00
Steering and hoist hydraulic piping ............................................................................................. 2
Dump body control ...................................................................................................................... 4
Hydraulic tank ............................................................................................................................. 5
Steering valve.............................................................................................................................. 6
Crossover relief valve.................................................................................................................. 10
Steering cylinder.......................................................................................................................... 11
Steering control valve.................................................................................................................. 12
Hoist valve................................................................................................................................... 18
EPC valve ................................................................................................................................... 24
Hoist cylinder............................................................................................................................... 25
Hydraulic pump ........................................................................................................................... 26
Cab and its attachments SEN02298-00
Air conditioner ............................................................................................................................. 2
Machine monitor system ............................................................................................................. 2
Automatic shift control system .................................................................................................... 2
Transmission controller ............................................................................................................... 6
Automatic emergency steering system ....................................................................................... 20
Automatic suspension system..................................................................................................... 22
Retarder control system .............................................................................................................. 25
Payload meter (Card type) ...................................................................................................... 2
VHMS controller related .............................................................................................................. 2
Sensors, switches ....................................................................................................................... 26
20 Standard value table

Standard service value table SEN02527-00
Standard value table for engine .................................................................................................. 2
Steering and hoist hydraulic circuit diagram................................................................................ 3
Standard value table for machine................................................................................................ 4
30 Testing and adjusting

Testing and adjusting, Part 1 SEN02528-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Testing engine speed .................................................................................................................. 6
Testing air supply pressure (boost pressure) .............................................................................. 7
Testing exhaust temperature....................................................................................................... 8
Testing exhaust gas color............................................................................................................ 10
Adjustment of valve clearance .................................................................................................... 12
Testing of compression pressure ................................................................................................ 14
Testing blow-by pressure ............................................................................................................ 17
Testing engine oil pressure ......................................................................................................... 18
Handling of fuel system devices.................................................................................................. 19
HD465-7R, HD605-7R 5
Releasing residual pressure from fuel system ............................................................................ 19

Testing of fuel pressure ............................................................................................................... 20
Cylinder cut-out mode operation ................................................................................................. 21
No-injection cranking................................................................................................................... 21
Testing of fuel return rate and fuel leakage ................................................................................. 22
Bleeding air from fuel circuit ........................................................................................................ 24
Testing the fuel circuit for leakage ............................................................................................... 25
Replacing and adjusting of fan belt ............................................................................................. 26
Replacing and adjusting of alternator and air conditioner compressor belt................................. 27
Testing torque converter stall speed............................................................................................ 3
Testing power train oil pressure................................................................................................... 4
Adjusting transmission speed sensor.......................................................................................... 11
Testing and adjusting brake oil pressure ..................................................................................... 12
Testing of accumulator nitrogen gas pressure and procedure for
charging accumulator with nitrogen gas .................................................................................. 15
Testing brake performance.......................................................................................................... 18
Bleeding air from brake circuit..................................................................................................... 20
Testing wear of front brake pad ................................................................................................... 21
Testing wear of rear brake disc ................................................................................................... 22
Method of releasing parking brake in an emergency .................................................................. 23
Testing and adjusting front suspension cylinder.......................................................................... 24
Testing and adjusting rear suspension cylinder........................................................................... 28
Testing and adjusting front suspension cylinder (Automatic suspension specification) .............. 32
Testing and adjusting hydraulic pressure in steering/hoist circuit................................................ 33
Testing and adjusting oil pressure in dump EPC circuit .............................................................. 36
Air bleeding from steering cylinder .............................................................................................. 37
Procedure for raising dump body in emergency.......................................................................... 38
Adjusting body positioner sensor ................................................................................................ 39
Handling of high voltage circuit of engine controller.................................................................... 40
Adjusting transmission controller................................................................................................. 40
Method for emergency escape at electrical system failure ......................................................... 41
Setting and adjusting of devices.................................................................................................. 2
Special functions of machine monitor (EMMS)............................................................................ 14
Special functions of machine monitor (EMMS)............................................................................ 2
VHMS controller initial setting procedure .................................................................................... 2
Precautions for replacing VHMS controller ................................................................................. 23
Pm Clinic check sheet ................................................................................................................. 29
Initial setting of payload meter..................................................................................................... 32
Setting of payload meter built in VHMS....................................................................................... 33
Setting of card-type payload meter (PLM- ) after installation or replacement............................ 41
40 Troubleshooting
Failure code table and fuse locations SEN02717-00
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 13
General information on troubleshooting SEN02718-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Contents of troubleshooting table................................................................................................ 6
Connection table for connector pin numbers............................................................................... 8
6 HD465-7R, HD605-7R
T-adapter box and T-adapter table .............................................................................................. 37

Troubleshooting by failure code, Part 1 SEN02533-00
Failure code [1500L0] (Dual engagement).................................................................................. 3
Failure code [15B0NX] (Transmission oil filter: Clogging)........................................................... 4
Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation) ....................................... 6
Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) ....................................... 6
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)................. 7
Failure code [15G0MW] (R clutch: Slipping) ............................................................................... 8
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) ................ 10
Failure code [15H0MW] (Hi clutch: Slipping) .............................................................................. 12
Failure code [15J0MW] (Lo clutch: Slipping)............................................................................... 14
Failure code [15K0MW] (1st clutch: Slipping) ............................................................................. 16
Failure code [15L0MW] (2nd clutch: Slipping) ............................................................................ 18
Failure code [15M0MW] (3rd clutch: Slipping) ............................................................................ 20
Failure code [15N0MW] (4th clutch: Slipping)............................................................................. 22
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) .... 24
Failure code [15SBMA] (R clutch solenoid: Malfunction) ............................................................ 26
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) ... 28
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ........................................................... 32
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) ... 34
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) .......................................................... 38
Failure code [15SEL1] (1st clutch solenoid:
Fill signal is ON when command current is OFF) .................................................................... 40
Failure code [15SEMA] (1st clutch solenoid: Malfunction).......................................................... 44
Failure code [15SFL1] (2nd clutch solenoid:
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)......................................................... 6
Failure code [15SGL1] (3rd clutch solenoid:
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ......................................................... 12
Failure code [15SHL1] (4th clutch solenoid:
Failure code [15SHMA] (4th clutch solenoid: Malfunction) ......................................................... 18
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).................................................... 20
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) .................................... 21
Failure code [2G42ZG] (Accumulator: Oil pressure reduction (Front)) ....................................... 24
Failure code [2G43ZG] (Accumulator: Oil pressure reduction (Rear)) ........................................ 24
Failure code [989A00] (Engine over run prevention command signal: Operating) ..................... 25
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated) ............................. 25
Failure code [A570NX] (Engine oil filter: Clogging) ..................................................................... 26
Failure code [AA10NX] (Air cleaner element: Clogging) ............................................................. 28
Failure code [AB00MA] (Alternator: Malfunction)........................................................................ 30
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure:
Lowering of oil pressure) ......................................................................................................... 32
Failure code [B@BAZK] (Engine oil: Level too low).................................................................... 34
Failure code [B@BCNS] (Engine: Overheat) .............................................................................. 36
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level) ................................. 38
Failure code [B@BFZK] (Lowering of fuel level) ......................................................................... 40
Failure code [B@C7NS] (Brake cooling oil: Overheating (Rear)) ............................................... 41
Failure code [B@CENS] (Overheating of torque converter oil)................................................... 42
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) ........................................ 43
Failure code [B@JANS] (Steering oil temperature: Overheat).................................................... 44
Failure code [CA111] (Abnormality in engine controller) ............................................................. 4
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .................................................. 6
Failure code [CA122] (Charge pressure sensor high error) ........................................................ 8
HD465-7R, HD605-7R 7
Failure code [CA123] (Charge pressure sensor low error).......................................................... 10

Failure code [CA131] (Throttle sensor high error)....................................................................... 12
Failure code [CA132] (Throttle sensor low error) ........................................................................ 14
Failure code [CA135] (Engine oil pressure sensor high error) .................................................... 16
Failure code [CA141] (Engine oil pressure sensor low error)...................................................... 18
Failure code [CA144] (Coolant temperature sensor high error) .................................................. 20
Failure code [CA145] (Coolant temperature sensor low error).................................................... 22
Failure code [CA153] (Charge temperature sensor high error)................................................... 24
Failure code [CA154] (Charge temperature sensor low error) .................................................... 26
Failure code [CA187] (Sensor power supply 2 low error)............................................................ 26
Failure code [CA212] (Engine oil temperature sensor high error)............................................... 28
Failure code [CA213] (Engine oil temperature sensor low error) ................................................ 30
Failure code [CA221] (Atmospheric pressure sensor high error) ................................................ 32
Failure code [CA222] (Atmospheric pressure sensor low error) ................................................. 34
Failure code [CA227] (Sensor power supply 2 high error) .......................................................... 36
Failure code [CA234] (Engine overspeed) .................................................................................. 38
Failure code [CA238] (Ne speed sensor power supply error) ..................................................... 40
Failure code [CA263] (Fuel temperature sensor high error)........................................................ 42
Failure code [CA265] (Fuel temperature sensor low error) ......................................................... 44
Failure code [CA271] (PCV1 Short circuit).................................................................................. 46
Failure code [CA272] (PCV1 Disconnection) .............................................................................. 48
Failure code [CA273] (PCV2 Short circuit).................................................................................. 50
Failure code [CA274] (PCV2 Disconnection) .............................................................................. 52
Failure code [CA322] (Injector #1 open/short error).................................................................... 54
Failure code [CA342] (Calibration code inconsistency)............................................................... 66
Failure code [CA351] (Injectors drive circuit error)...................................................................... 66
Failure code [CA352] (Sensor power supply 1 low error)............................................................ 67
Failure code [CA386] (Sensor power supply 1 high error) .......................................................... 68
Failure code [CA431] (Trouble in idle validation switch).............................................................. 4
Failure code [CA432] (Idle validation action error) ...................................................................... 6
Failure code [CA441] (Battery voltage low error) ........................................................................ 6
Failure code [CA442] (Battery voltage high error)....................................................................... 7
Failure code [CA449] (Common rail pressure high error 2) ........................................................ 7
Failure code [CA451] (Common rail pressure sensor high error)................................................ 8
Failure code [CA452] (Common rail pressure sensor low error) ................................................. 10
Failure code [CA553] (Common rail pressure high error 1) ........................................................ 11
Failure code [CA554] (Common rail pressure sensor: In-range error) ........................................ 12
Failure code [CA559] (Supply pump pressure very low error) .................................................... 13
Failure code [CA689] (Engine Ne speed sensor error) ............................................................... 16
Failure code [CA731] (Engine Bkup speed sensor phase error)................................................. 18
Failure code [CA757] (All continuous data lost error).................................................................. 19
Failure code [CA778] (Engine Bkup speed sensor error)............................................................ 20
Failure code [CA1633] (KOMNET datalink timeout error) ........................................................... 22
Failure code [CA2185] (Throttle sensor supply voltage high error) ............................................. 24
Failure code [CA2186] (Throttle sensor power supply low error) ................................................ 26
Failure code [CA2249] (Supply pump pressure very low error 2) ............................................... 27
Failure code [CA2555] (Intake heater relay voltage low error) .................................................... 28
Failure code [CA2556] (Intake heater relay voltage high error) .................................................. 30
8 HD465-7R, HD605-7R

Failure code [D19HKB] (Stop lamp relay output system: Short circuit)....................................... 3
Failure code [D5ZKKZ] (Front brake cut-off solenoid valve:
Disconnection, short circuit or short circuit to power sorce line).............................................. 4
Failure code [DAF9KM] Wrong connection of connector ............................................................ 6
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor):
Abnormal communication)....................................................................................................... 8
Failure code [DAQ0KK] (Transmission controller direct power supply:
Lowering of source voltage) .................................................................................................... 10
Failure code [DAQ0KT] (Transmission controller nonvolatile memory:
Abnormality in controller)......................................................................................................... 12
Failure code [DAQ2KK] (Transmission controller solenoid power source:
Power source voltage too low) ................................................................................................ 13
Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)................ 14
Failure code [DAQRKR] (Abnormality in CAN communication (Transmission)) ......................... 14
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) .......................... 15
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller) ...... 15
Failure code [DB12KK] (Retarder controller solenoid power source:
Power source system trouble) ................................................................................................. 16
Failure code [DB13KK] (Retarder controller battery direct power source:
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 20
Failure code [DB1RKR] (CAN communication (retarder controller):
Communication disabled) ........................................................................................................ 22
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)............................ 24
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ... 26
Failure code [DBBRKR] (Abnormality in CAN communication (VHMS))..................................... 29
Failure code [DBC2KK] (ABS controller solenoid power source:
Power source system trouble) ................................................................................................. 30
Failure code [DBC3KK] (ABS controller battery direct power source:
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)............................... 34
Failure code [DBCRKR] (Abnormality in CAN communication (ABS))........................................ 34
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................. 35
Failure code [DDD7KX] (Trouble in travel speed setting switch system:
Out of input signal range) ........................................................................................................ 36
Failure code [DDD8KA] (ARSC system switch system: Disconnection) (If equipped) ................ 38
Failure code [DDD8KB] (ARSC system switch system: Short circuit) (If equipped) ................... 40
Failure code [DDD9KA] (ABS system switch system: Disconnection) ........................................ 42
Failure code [DDD9KB] (ABS system switch system: Short circuit) ........................................... 44
Failure code [DDDAKA] (ASR system switch: Disconnection).................................................... 46
Failure code [DDDAKB] (ASR system switch: Short circuit) ....................................................... 48
Failure code [DDP6L4] (Service brake pressure switch trouble (Rear)) ..................................... 50
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) ..................................................... 52
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)...................................................... 54
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) .................................................... 56
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) ................................................... 58
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) ................................................... 60
Failure code [DDTNKA] (R clutch fill switch: Disconnection) ...................................................... 62
Failure code [DDTPKA] (4th clutch fill switch: Disconnection) .................................................... 64
Failure code [DF10KA] (Gear shift lever: Disconnection) ........................................................... 66
Failure code [DF10KB] (Gear shift lever: Short circuit) ............................................................... 69
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range) ........ 72
Failure code [DGR2KZ] (Retarder oil temperature sensor system trouble :
Ground fault (Rear wheel)) ...................................................................................................... 74
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................. 76
Failure code [DGT1KX] (Torque converter oil temperature sensor:
Out of input signal range) ........................................................................................................ 78
HD465-7R, HD605-7R 9

Failure code [DHP6KA] (Suspension pressure sensor system: Disconnection right rear).......... 3
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble:
Out of input signal range (Right rear)) ..................................................................................... 4
Failure code [DHP6KY] (Suspension pressure sensor system: Short circuit (Right rear)).......... 6
Failure code [DHP6KZ] (Suspension pressure sensor system:
Disconnection or ground fault (Right rear)).............................................................................. 6
Failure code [DHP7KA] (Suspension pressure sensor system: Disconnection (Left rear)) ........ 7
Out of input signal range) (Left rear)........................................................................................ 8
Failure code [DHP7KY] (Suspension pressure sensor system: Short circuit (Left rear)) ............ 10
Disconnection or ground fault (Left rear)) ................................................................................ 11
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) ........ 12
Failure code [DHT5L6] (Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal) ............................................................... 14
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) ...... 16
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range)....... 18
Failure code [DJF1KA] (Fuel level sensor: Disconnection) ......................................................... 20
Failure code [DK30KX] (Steering angle potentiometer: Trouble (Disconnection)) ...................... 21
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with swich signal) ........................................................... 22
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) ......... 26
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) 28
Failure code [DK54KX] (Body positioner sensor: Out of input signal range)............................... 30
Failure code [DKD0L6] (Failure in steering speed sensor) ......................................................... 32
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) ..................................... 34
Failure code [DKH1KX] (Pitch angle sensor: Abnormality (Disconnection or short circuit))........ 36
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)....................... 38
Failure code [DLF1LC] (Transmission input shaft speed sensor:
Disagreement of revolution speed signal) ............................................................................... 40
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)........... 42
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear)) ................................ 4
Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear))................................. 6
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear))........................................... 8
Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear)) ............................... 9
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear)) .................................. 10
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear)).............................................. 12
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear)) ............................................. 14
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear)) .................................. 15
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)..................... 16
Failure code [DLT3LC] (Transmission output shaft speed sensor:
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection)..................... 20
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) ........................ 22
Failure code [DV00KB] (Buzzer output: Short circuit) ................................................................. 24
Failure code [DW2AKA] (Main pressure variable valve output: Disconnection).......................... 26
Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault) .................. 28
Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short) ....................... 30
Failure code [DW2AL1] (Main pressure variable valve: Defective reset) .................................... 32
Failure code [DW2ALH] (Main pressure variable valve: Malfunction) ......................................... 34
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit) ................................................................................................. 36
Disconnection or short circuit) (If equipped) ............................................................................ 38
10 HD465-7R, HD605-7R
Failure code [DW72KZ] (Kick-out solenoid output system trouble:

Failure code [DW73KZ] (Failure in hoist select valve output system:
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble:
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating)) ........................ 46
Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection)............................... 48
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault) ................................. 50
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit) .................................. 52
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate))...................... 53
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve:
Out of control).......................................................................................................................... 4
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve
output circuit: Disconnection) .................................................................................................. 6
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve:
Short circuit) ............................................................................................................................ 7
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line) ........................................................................................... 8
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve:
Malfunction) ............................................................................................................................. 9
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) ................................ 10
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit).................................... 12
Failure code [DX13KY] (Output circuit of hoist EPC valve:
Short circuit with power source line) ........................................................................................ 14
Failure code [DX17K4] (ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating))............................................................................................. 16
Failure code [DX17KA] (ASR proportional pressure reducing solenoid valve (right)
Failure code [DX17KB] (ASR proportional pressure reducing solenoid valve (right)
output circuit: Ground fault) ..................................................................................................... 20
Failure code [DX17KY] (ASR proportional pressure reducing solenoid valve (right)
output circuit: Short circuit) ...................................................................................................... 22
Failure code [DX17MA] (ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate)) ........................................................................................... 22
Failure code [DX18K4] (ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating))............................................................................................. 24
Failure code [DX18KA] (ASR proportional pressure reducing solenoid valve (left)
Failure code [DX18KB] (ASR proportional pressure reducing solenoid valve (left)
output circuit: Ground fault) ..................................................................................................... 28
Failure code [DX18KY] (ASR proportional pressure reducing solenoid valve (left)
output circuit: Short circuit) ...................................................................................................... 30
Failure code [DX18MA] (ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate)) ........................................................................................... 30
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ......................... 3
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit) ............................. 4
Failure code [DXH1KY] (Lockup clutch solenoid output circuit:
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection) ................................. 6
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ..................................... 8
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line) .... 10
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................. 14
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit) .................................... 16
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line) ... 18
HD465-7R, HD605-7R 11
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) ................................ 22
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit).................................... 24
Failure code [DXH4KY] (1st clutch solenoid output circuit:
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection) ............................... 30
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)................................... 32
Failure code [DXH5KY] (2nd clutch solenoid output circuit:
Short circuit in power source line)............................................................................................ 34
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)................................ 38
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ................................... 40
Failure code [DXH6KY] (3rd clutch solenoid output circuit:
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................. 46
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit) ...................................... 48
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)..... 50
Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection) ............................... 52
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit) ................................... 54
Failure code [DXHHKY] (4th clutch solenoid output circuit:
Troubleshooting of electrical system (E-mode) SEN02542-00
Before troubleshooting of electric system ................................................................................... 3
E-1 Engine does not start............................................................................................................ 5
E-2 Automatic preheating does not operate................................................................................ 8
E-3 Machine monitor does not display all, when starting switch is turned ON ............................ 12
E-4 Machine monitor does not operate when starting switch is OFF .......................................... 14
E-5 Alarm buzzer does not sound ............................................................................................... 16
E-6 Gauges of machine monitor, caution lamps or character display
section do not display properly. ............................................................................................... 18
E-7 A selection of the display in character display section cannot be changed .......................... 19
E-8 Power mode selecting function does not operate properly................................................... 22
E-9 AISS function does not operate properly .............................................................................. 23
E-10 Seat belt caution lamp does not display properly ............................................................... 24
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly................................ 25
E-12 Night illumination (lighting) does not work properly ............................................................ 28
E-13 Emergency steering does not operate................................................................................ 40
E-14 Hoist lever does not operate normally ................................................................................ 46
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02543-00
H-1 Machine does not start ......................................................................................................... 4
H-2 Machine does not travel smoothly (hunting)......................................................................... 6
H-3 Lockup cannot be cancelled ................................................................................................. 6
H-4 Excessive shock when starting or shifting excessive ........................................................... 7
H-5 Transmission does not shift up ............................................................................................. 8
H-6 Machine lacks power or speed when traveling..................................................................... 10
H-7 Time lag is excessive when starting or shifting gear ............................................................ 14
H-8 Torque converter oil temperature is high .............................................................................. 16
H-9 Torque converter oil pressure is low ..................................................................................... 17
H-10 Front brake is ineffective .................................................................................................... 18
H-11 Rear brake is ineffective ..................................................................................................... 19
H-12 Steering wheel is heavy...................................................................................................... 20
H-13 Steering wheel does not work............................................................................................. 21
H-14 Steering wheel vibrates ...................................................................................................... 22
H-15 Dump body lifting speed is slow ......................................................................................... 23
H-16 Dump body does not work.................................................................................................. 24
H-17 Excessive hydraulic drift of dump body .............................................................................. 25
12 HD465-7R, HD605-7R
Troubleshooting of engine (S-mode) SEN02544-00

Method of using troubleshooting chart ........................................................................................ 4
S-1 Starting performance of engine is poor................................................................................. 8
S-2 Engine does not start............................................................................................................ 9
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operation .............................................................................................. 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lack output (or lacks power) ..................................................................................... 15
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 16
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 18
S-9 Oil becomes dirty quickly...................................................................................................... 19
S-10 Fuel consumption is excessive........................................................................................... 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 21
S-12 Oil pressure drops .............................................................................................................. 22
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 23
S-14 Coolant temperature becomes too high (Overheating) ...................................................... 24
S-15 Abnormal noise is made ..................................................................................................... 25
S-16 Vibration is excessive ......................................................................................................... 26
90 Diagrams and drawings

Hydraulic circuit diagram SEN02313-00
Power train hydraulic circuit diagram .......................................................................................... 2
Steering and hoist hydraulic circuit diagram................................................................................ 3
Brake hydraulic circuit diagram ................................................................................................... 5
Electrical circuit diagram SEN02314-01
Electrical circuit diagram inside cab (1/2).................................................................................... 3
Electrical circuit diagram outside cab (2/2) ................................................................................. 5
Connectors table and arrangement drawing ............................................................................... 7
HD465-7R, HD605-7R 13
HD465-7R, HD605-7R Dump truck

Form No. SEN02285-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
14 HD465-7R, HD605-7R
SEN02286-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
HD465-7R, HD605-7R 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 HD465-7R, HD605-7R
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
HD465-7R, HD605-7R 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 HD465-7R, HD605-7R
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HD465-7R, HD605-7R 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 HD465-7R, HD605-7R
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
HD465-7R, HD605-7R 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 HD465-7R, HD605-7R
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
HD465-7R, HD605-7R 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 HD465-7R, HD605-7R
Handling electric equipment and hydraulic component 1

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).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HD465-7R, HD605-7R 11
3) 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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. 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-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face 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 com-
pressed 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 com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 HD465-7R, HD605-7R
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. 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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
HD465-7R, HD605-7R 13
2) Connecting connectors
1] 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 dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 HD465-7R, HD605-7R
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
HD465-7R, HD605-7R 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
1] 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
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 HD465-7R, HD605-7R
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HD465-7R, HD605-7R 17
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
(foreign 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
repairing 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 check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
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
refilling 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HD465-7R, HD605-7R
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 contaminants 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 equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HD465-7R, HD605-7R 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 HD465-7R, HD605-7R
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
HD465-7R, HD605-7R 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 HD465-7R, HD605-7R
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
HD465-7R, HD605-7R 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 HD465-7R, HD605-7R
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
HD465-7R, HD605-7R 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
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
26 HD465-7R, HD605-7R
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a 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 idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
HD465-7R, HD605-7R 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 HD465-7R, HD605-7R
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the 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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a 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. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HD465-7R, HD605-7R 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 HD465-7R, HD605-7R
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
HD465-7R, HD605-7R 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

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
a Fig. A a Fig. B
32 HD465-7R, HD605-7R
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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} 127.4 {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}
HD465-7R, HD605-7R 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 HD465-7R, HD605-7R
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
HD465-7R, HD605-7R 35
Conversion table 1
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), and then draw a hori-
zontal 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 2 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 it 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.
Millimeters to inches (B)

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)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 HD465-7R, HD605-7R
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
Liters to U.S. Gallons

1 l = 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
HD465-7R, HD605-7R 37
Liters to U.K. Gallons

1 l = 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 7.699 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
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
38 HD465-7R, HD605-7R
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HD465-7R, HD605-7R 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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 81 177.8
–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 60 140.0 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
40 HD465-7R, HD605-7R

© 2006 KOMATSU
All Rights Reserved
42 HD465-7R, HD605-7R
SEN02289-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
01 Specification 1
Specification and technical data
Specification drawing ...................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Fuel, coolant and lubricants .......................................................................................................................... 10
HD465-7R, HD605-7R 1
SEN02289-00 01 Specification
Specification drawing 1
HD465-7R
HD605-7R
2 HD465-7R, HD605-7R
Specifications 1
Machine model HD465-7R
Serial No. 15001 and up
Empty kg 43,100
Max. load kg 55,000
Gross kg 98,180
Weight
(front) kg 20,260 (47%)

Empty
distribution
(rear) kg 22,840 (53%)

Weight
(front) kg 31,420 (32%)

Gross
(rear) kg 66,760 (68%)
3
Struck m 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 604
Model KOMATSU SAA6D170E-5
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} 3,324/1,400 {339/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 196 {146}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 2 units
HD465-7R, HD605-7R 3
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)

Axle type
Suspension
Rear axle Full floating
Front axle Hydropneumatic

(Automatic damping force selection type)
Suspension method
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
Breke system
Rear axle Oil cooled multiple disc brake, Hydraulically controlled
Multiple disc wet type disc brake,

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

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
HD465-7R, HD605-7R 5

Empty kg 46,200
Max. load kg 63,000
Gross kg 109,280
Weight
(front) kg 21,710 (47%)

Empty
distribution
(rear) kg 24,490 (53%)

Weight
(front) kg 34,970 (32%)

Gross
(rear) kg 74,310 (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 604
Model KOMATSU SAA6D170E-5
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} 3,324/1,400 {339/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 196 {146}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 2 units
6 HD465-7R, HD605-7R
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)

Axle type
Suspension
Rear axle Full floating
Front axle Hydropneumatic

(Automatic damping force selection type)
Suspension method
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/cm }
2 686 {7.0}
Front wheel Single dry disc type, Hydraulically controlled

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

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

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
8 HD465-7R, HD605-7R
Weight table 1
This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model HD465-7R HD605-7R
Serial Number 15001 and up 16001 and up
Engine assembly 3,030 3,030

Output shaft assembly 123 123
Radiator assembly 405 405
Fuel tank 294 294
Torque converter assembly 412 412
Transmission assembly 1,264 1,264
Drive shaft assembly (front) 26 26
Drive shaft assembly (rear) 62 62
Rear axle assembly 6,293 6,293
• Differential 774 774
• Final drive (one-side) 1,421 1,421
• Rear brake (one-side) 721 721
Front axle (one-side) 330 330
Front brake (one-side) 142 142
Front suspension cylinder 460 460
Rear suspension cylinder 176 176
Frame 4,680 4,680
Cab (Platform) 1,104 1,104
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 (SDR(30)–100+100) 40 40
Hydraulic pump (SDR(30)–80+80(1)6) 38 38
Hydraulic pump (SDR(30)100+(1)25) 26 26
Dump body 10,730 13,418
HD465-7R, HD605-7R 9
Fuel, coolant and lubricants 1
10 HD465-7R, HD605-7R
Engine Oil Transmission Steering, Front Rear Differential

Pan Case Hoist Oil Tank Suspension Suspension Case
Specified 16.5 each for 11.3 each for

76 318 180 95
capacity ( ) right and left right and left
Refill capacity
70 215 122 — — 95
( )
Final drive Cooling

Fuel tank
case system
Specified oil 32 each for

780 157
level ( ) right and left
Refill capacity 21 each for

— —
( ) right and left
Notice
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection
device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it
requires high precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability.
Note 1: HTHS ( High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal
to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of
pins and bushings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)

1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC
has excellent anticorrosion, antifreeze and cooling propertiesand can be used continuously for 2 years or
4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Mixing rate of water and super cool-
ant".
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never
dilute with water)
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercool-
ant between 30% and 68%.
HD465-7R, HD605-7R 11
Mixing rate of water and super coolant
Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Liters 47.1 55.0 62.8 70.7 78.5

Amount of antifreeze
US gal 12.45 14.54 16.60 18.70 20.75
Liters 109.9 102.0 94.2 86.3 78.5

Amount of water
US gal 29.05 26.96 24.90 22.80 20.75
Volume ratio % 30 35 40 45 50
12 HD465-7R, HD605-7R

© 2006 KOMATSU
All Rights Reserved
14 HD465-7R, HD605-7R
SEN02291-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler .............................. 2
Fuel system..................................................................................................................................................... 4
Brake oil cooler ............................................................................................................................................... 5
Output shaft .................................................................................................................................................... 6
HD465-7R, HD605-7R 1
SEN02291-00 10 Structure, function and maintenance standard
Radiator, torque converter oil cooler, after cooler, work equipment oil
cooler, fuel cooler 1
1. Pick-up for radiator coolant level sensor Specifications

2. Upper tank Radiator
3. Lower tank AL. Louver 4 Lines
4. Core Total radiation surface: 142.86 m2
5. Work equipment oil cooler
6. After cooler Work equipment oil cooler
7. Aircon conditioner Core type: CF40-1
Radiation surface: 2.90 m2
A: Coolant inlet port
B: Coolant outlet port After cooler
Heat radiation area: 52.13 m2
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Fuel system 1
1. Fuel main filter

2. Fuel pre-filter (with water separator)
3. Over flow
4. Nozzle spill
5. Feed pump
6. Fuel tank
7. Water separator
4 HD465-7R, HD605-7R
Brake oil cooler 1
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
HD465-7R, HD605-7R 5
Output shaft 1
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
6 HD465-7R, HD605-7R
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between flywheel size Shaft Hole clearance limit
1
and bearing
–0.015 –0.010 –0.045 –
100 0.02
–0.015 –0.045 0.005
Clearance between shaft and –0.010 –0.015 –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 –0.1
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
HD465-7R, HD605-7R 7

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R
SEN02292-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Power train system, Part 1
Power train skeleton ....................................................................................................................................... 2
Drive shaft....................................................................................................................................................... 4
Torque converter and transmission hydraulic piping....................................................................................... 6
Brake cooling oil control valve (BCV).............................................................................................................. 8
Torque converter ........................................................................................................................................... 10
Torque converter valve.................................................................................................................................. 17
Transmission................................................................................................................................................. 19
Transmission control valve............................................................................................................................ 35
ECMV............................................................................................................................................................ 36
HD465-7R, HD605-7R 1
Power train skeleton 1
2 HD465-7R, HD605-7R
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling pump
(SDR(30)100+100)
5. Torque converter transmission charge pump
and brake cooling brake control pump
(SDR(30)100+SA(1)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
(SDR(30)80+80+SB(1)6)
HD465-7R, HD605-7R 3
Drive shaft 1
1. Front drive shaft Outline

2. Rear drive shaft q 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).
4 HD465-7R, HD605-7R
Torque converter and transmission hydraulic piping 1
6 HD465-7R, HD605-7R
1. Torque converter
2. Transmission
3. Oil filler tube
4. Hydraulic pump (SDR(30)100+25)
5. Torque converter valve
6. Transmission oil filter
7. Brake cooling oil control valve (BCV)
HD465-7R, HD605-7R 7
Brake cooling oil control valve (BCV) 1
1. Pilot relief valve assembly Function

2. Body When the retarder is not being used, this valve
3. Solenoid valve bypasses part of the brake cooling oil to reduce the
4. Main valve spool power loss when traveling. The main valve spool is
actuated by switching the solenoid vavle ON/OFF.
A: Pilot port If any abnormal pressure is generated in the
B: Pilot port hydraulic circuit, which caused by abnormal in the
S: To tank rear retarder or in the oil cooler etc., the pilot relief
P: Pilot port valve is actusted, and this actuates the main relief
Q: From pump valve, so the brake cooling valve also acts as an
R: To tank unload valve.
8 HD465-7R, HD605-7R
Torque converter 1
A: Main oil pressure pickup port Specifications

B: Torque converter oil inlet port Type : 3-element, 1-stage, 2-phase with
C: Torque converter inlet oil pressure pickup port modulation and lockup clutch
D: Torque converter oil outlet port Lockup clutch : Wet type multiple disc clutch
E: To the transmission control valve hydraulic control (with modula-
F: To the lockup clutch tion valve)
G: Torque converter outlet oil pressure pickup port Stall torque ratio: 2.25
H: To the transmission lubrication circuit
1. PTO gear (number of teeth: 91)

2. Brake cooling pump mounting port
3. Steering, hoist, hoist control pump mounting
port
4. Torque converter, transmission charge, brake
cooling, transmission lubrication, brake control
pump mounting port
5. Torque converter valve
6. Torque converter intermediate oil pressure
sensor
7. Torque converter outlet oil temperature sensor
10 HD465-7R, HD605-7R
1. Coupling 10. Stator shaft

2. Input shaft (number of teeth: 108) 11. Sleeve
3. Case 12. Inner race
4. Drive case 13. Free wheel
5. Boss 14. Stator
6. Turbine 15. Lockup clutch disc
7. Outer race 16. Lockup clutch piston
8. Pump 17. Lockup clutch housing
9. Retainer 18. Retainer
HD465-7R, HD605-7R 11
12 HD465-7R, HD605-7R
Unit: mm
Standard size Tolerance Repair limit
Outer diameter of oil seal
1 –0.087
contact surface of the coupling 110 109.8
–0.087
Inner diameter of the seal ring
+0.025
2 contact surface of the input 35 35.1
+0.025
shaft
Clearance between clutch size Shaft Hole clearance limit
3
housing and piston (outside) –0.5 +0.097 0.500 –
420 0.88
–0.7 +0.097 0.797
Clearance between clutch –0.110 +0.081 0.110 –
4 295 0.30
housing and piston (inside) –0.191 +0.081 0.272
Inner diameter of the seal ring +0.040
5 135 135.5
contact surface of the retainer +0.040
Inner diameter of the seal ring +0.030
6 75 75.1
contact surface of the sleeve +0.040
–0.1
Wear of the stator Width 3.95 3.55
7 –0.1
shaft seal ring
Thickness 5.1 ±0.1 4.59
Replace
Inner diameter of outer race
8 free wheel transmission sur- 127.844 ±0.009 127.874
face
Outer diameter of inner race
9 free wheel transmission sur- 108.883 ±0.013 108.853
face
Inner diameter of sliding por- +0.012
10 109 109.04
tion of bushing (*1) –0.010
Thickness of sliding portion of –0.1
11 5 4.5
bushing (*1) –0.1
12 Thickness of the clutch disc 5.4 ±0.1 4.8
Backlash between input shaft
13 0.17 – 0.45
and PTO gear
Clearance between PTO gear size Shaft Hole clearance limit
14
and bearing +0.018 –0.015 –0.030 –
50 —
+0.002 –0.012 –0.002
Clearance between bearing –0.015 +0.004 –0.018 –
15 90 —
and case –0.015 –0.018 0.019
*1. Refer to “Method of measuring dimension of bushing sliding portion“
HD465-7R, HD605-7R 13
Method of measuring dimension of bushing sliding portion
Measure inner diameter (A) and thickness (B) of

bushing sliding portion with output side bushing (2)
and input side bushing (3) installed to outer race
(1).
14 HD465-7R, HD605-7R
Power transmitting route
When lockup clutch is "disengaged" When lockup clutch is "engaged"
q When the lockup clutch is “disengaged“, drive q When the lockup clutch is “engaged“, drive
case (4) and turbine (6) are disconnected, and case (4) and turbine (6) are connected, and
the torque converter functions as normal. stator (9) is dragged and turned by the pump
q The engine power is transferred through the (5) and turbine (6).
damper and drive shaft to coupling (1). q The engine power is transferred through the
q The power transferred to coupling (1) rotates damper and drive shaft to coupling (1).
input shaft (2), clutch housing (3), drive case q The power transferred to coupling (1) rotates
(4) and pump (5) integrally. input shaft (2), clutch housing (3), drive case
q The power transferred to the pump (5) rotates (4) and pump (5) integrally.
turbine (6) using the oil as a medium. q As the lock up clutch is engaged, the power
q The power is transferred from turbine (6) to transferred to the drive case (4) directly rotates
boss (7) and to transmission input shaft (8) that turbine (6).
is splined to boss (7). q The power is transferred from turbine (6) to
boss (7) and to transmission input shaft (8) that
is splined to boss (7).
HD465-7R, HD605-7R 15
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows into inlet port (A), goes through the oil
passages of stator shaft (1), and flows into
pump (2).
q The oil is given centrifugal force by pump (2)
and flows into turbine (3) to transmit its energy
to turbine (3).
q The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4)
and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
transmission.
16 HD465-7R, HD605-7R
Torque converter valve 1
Unit: mm
Clearance between the torque size clearance limit
Shaft Hole
1 converter relief valve and the
valve body –0.035 +0.016 0.035 –
32 0.081
–0.045 +0.016 0.061
Clearance between the main –0.035 +0.016 0.035 –
2 32 0.081
relief valve and the valve body –0.045 +0.016 0.061
Clearance between the main
–0.030 +0.011 0.030 –
3 pressure variable valve 14 0.071
–0.040 +0.016 0.051
and the valve body
Replace
Installation Installation Installation
Free length Free length
4 Main relief valve spring length load load
1213.2 N 1153.8 N
123 99.5 119.3
{123.8 kg} {117.6 kg}
Torque converter relief valve 331.2 N 315.0 N
5 137 93.5 132.9
spring {33.8 kg} {32.1 kg}
Poppet spring 32.0 N 30.8 N
6 26 17.0 25.2
(T/C relief and main relief) {3.3 kg} {3.1 kg}
Main pressure variable valve 108.0 N 102.4 N
7 40.5 33.0 39.3
spring {11.0 kg} {10.5 kg}
HD465-7R, HD605-7R 17
Main relief valve

Outline
This valve has a main relief pressure changing function. It lowers the main relief pressure in the high gear
speeds (F4 – F7) where the clutch holding pressure is low to reduce the pump load, thus the fuel consump-
tion is reduced.
Principle of operation
When solenoid is "deenergized" When solenoid is "energized"
q While no current is supplied to solenoid (1), q If a current is supplied to solenoid (1), the oil
chambers (A) and (B) are connected and the pressure in chamber (A) increases and valve
oil pressure decreases. (2) is pushed to the left. As a result, the drain
q If the oil pressure in chambers (A) and (B) is circuit of chamber (B) is blocked and the oil
low, the hydraulic force in chamber (C) of main pressure in chamber (B) increases.
relief valve (4) is balanced with the force of q If the oil pressure in chamber (B) increases,
spring (5), thus the oil pressure is regulated. the hydraulic force in chamber (B) of main
relief valve (4) is balanced with the force of
spring (5), thus the oil pressure is regulated.
q Since the diameter of piston (3) is larger than
that of chamber (C), the oil pressure is regu-
lated lower when solenoid (1) is "energized"
than when solenoid (1) is "deenergized".
18 HD465-7R, HD605-7R
Transmission 1
A: Speed sensor (for input shaft speed) 1. Transmission input shaft

B: Speed sensor (for intermediate shaft speed) 2. Transmission control valve
C: Speed sensor (for output shaft speed) 3. Transmission output shaft
D: Lubricating oil temperature sensor 4. Strainer
E: Lubricating oil pressure pickup port 5. Drain valve
F: To pump (suction)
G: To lockup
H: From torque converter (main circuit)
J: From torque converter (lubrication circuit)
K: From oil cooler
L: From torque converter (drain circuit)
M: Retarder relief valve
N: Lubricating oil relief valve
P: To breather
HD465-7R, HD605-7R 19
20 HD465-7R, HD605-7R
1. Transmission input shaft Outline

2. H sun gear (number of teeth: 34) q The transmission consists of planetary gear
3. H ring gear (hub) systems and disc clutches and has “7 forward
4. H clutch gear speeds and 1 reverse gear speeds“.
5. H planetary pinion (number of teeth: 32) q Among the 7 sets of planetary gear system
6. H Carrier and disc clutches of the transmission, 2
7. L ring gear (hub) clutches are fixed hydraulically with the ECMV
8. L clutch to select 1 rotating direction and gear speed.
9. H ring gear (number of teeth: 98) q The transmission transmits the power received
10. L clutch housing by the transmission input shaft to the output
11. 4th clutch housing shaft while changing the gear speed (forward
12. 4th clutch drum 1st-7th or reverse 1st) by any combination of
13. 4th clutch the H, L, R clutches and 4 speed clutches.
14. 4th ring gear (hub)
15. 3rd planetary pinion (number of teeth: 21) Number of plates and disc used
16. 3rd clutch
17. 3rd ring gear (number of teeth: 93) Number of
Clutch No. Number of discs
plates
18. 3rd sun gear (number of teeth: 51)
19. R clutch H clutch 2 3
20. R planetary pinion (number of teeth: 21) L clutch 4 5
21. R sun gear (number of teeth: 41) 4th clutch 3 4
22. R ring gear (number of teeth: 93)
3rd clutch 3 4
23. 2nd clutch
24. 2nd ring gear (number of teeth: 105) R clutch 5 5
25. 2nd planetary pinion (number of teeth: 30) 2nd clutch 4 4
26. 2nd sun gear (number of teeth: 45) 1st clutch 4 4
27. 2nd and 1st carrier
28. 1st clutch
29. 1st ring gear (number of teeth: 104)
30. Transmission output shaft Combinations of clutches at respective gear
31. 1st planetary pinion (number of teeth: 38) speeds and reduction ratio
32. 1st clutch piston Reduction
Gear speed Operated clutches
33. 2nd clutch piston ratio
34. Intermediate shaft (1st sun gear number of Forward 1st
L x 1st 4.714
teeth: 28) speed
35. R clutch piston Forward 2nd
L x 2nd 3.333
36. R planetary pinion (number of teeth: 21) speed
37. 3rd and R carrier Forward 3rd
H x 2nd 2.475
38. 4th clutch piston speed
39. L clutch piston Forward 4th
L x 3rd 1.825
40. H clutch piston speed
41. 3rd clutch piston Forward 5th
H x 3rd 1.355
speed
Forward 6th
L x 4th 1.000
speed
Forward 7th
H x 4th 0.742
speed
Reverse 1st
LxR 3.969
speed
HD465-7R, HD605-7R 21
22 HD465-7R, HD605-7R
Unit: mm
Installation Installation Installation
Free length Free length
1 H clutch spring length load load
70.6 N 60.0 N
40.4 32.0 38.0
{7.2 kg} {6.1 kg}
48.9 N 41.6 N
2 3rd clutch spring 52.0 49.1 48.9
{5.0 kg} {4.2 kg}
113.5 N 96.6 N
3 R clutch spring 87.5 79.5 82.3
{11.6 kg} {9.9 kg}
113.8 N 97.1 N
4 2nd clutch spring 68.0 57.85 63.9
{11.6 kg} {9.9 kg}
157.8 N 134.1 N
5 1st clutch spring 75.0 64.4 70.5
{16.1 kg} {13.7 kg}
Total thickness of 3 discs and Standard size Tolerance Repair limit
6
2 plates for H clutch 27.8 ±0.22 25.8
Total thickness of 5 discs and
7 45.0 ±0.30 42.0
4 plates for L clutch
8 35.0 ±0.26 32.3
3 plates for 4th clutch
Total thickness of 4 discs and Replace
9 36.6 ±0.26 33.9
3 plates for 3rd clutch
10 52.0 ±0.32 47.7
5 plates for R clutch
11 44.8 ±0.28 42.1
4 plates for 2nd clutch
12 44.8 ±0.28 42.1
4 plates for 1st clutch
H,3rd,R,
5.4 ±0.10 4.8
13 Thickness of a disc 2nd,1st
L,4th 5.0 ±0.10 4.4
H,2nd,1st 5.8 ±0.10 5.6
Thickness of a
14 L,4th,
plate 5.0 ±0.10 4.8
3rd,R
Wear of the trans- –0.01
Width 2.56 2.30
15 mission input shaft –0.03
seal ring (small) Thickness 1.7 ±0.10 1.55
Wear of the trans- –0.01
Width 3.0 2.70
16 mission input shaft –0.03
seal ring (large) Thickness 3.1 ±0.10 2.95
HD465-7R, HD605-7R 23
Unit: mm
Wear of the H car-
–0.01
17 rier and 4th ring Width 3.95 3.56
–0.01
gear seal ring
Thickness 4.95 ±0.1 4.8
–0.01
Wear of the 3rd sun Width 4.0 3.6
18 –0.03
gear seal ring
Thickness 4.6 ±0.12 4.45
Wear of the L and –0.01
Width 4.0 3.6
19 4th clutch collar –0.03
seal ring Thickness 5.1 ±0.12 4.95
Wear of the 3rd –0.01
Width 4.0 3.6
20 and R carrier seal –0.04
ring Thickness 6.3 ±0.15 6.15
Wear of the 2nd –0.01
Width 4.0 3.6
21 and 1st carrier seal –0.04
Width 3.95 3.56
Width 4.0 3.6
ring Thickness 4.0 ±0.15 3.85 Replace
Backlash between H sun gear
24 0.13 – 0.36
and planetary pinion
Backlash between H planetary
25 0.16 – 0.41
pinion and ring gear
Backlash between 3rd sun
26 0.14 – 0.36
gear and planetary pinion
Backlash between 3rd plane-
27 0.15 – 0.39
tary pinion and ring gear
Backlash between R sun gear
28 0.14 – 0.36
and planetary pinion
Backlash between R planetary
29 0.13 – 0.34
pinion and planetary pinion
Backlash between R planetary
30 0.15 – 0.39
pinion and ring gear
Backlash between 2nd sun
31 0.16 – 0.41
Backlash between 2nd plane-
32 0.16 – 0.41
Backlash between 1st sun
33 0.13 – 0.36
Backlash between 1st plane-
34 0.17 – 0.44
24 HD465-7R, HD605-7R
Unit: mm
Deterioration of disc internal
35 Repair limit: 0.3
teeth
Thickness of thrust washer Standard size Tolerance Repair limit
36 Replace
(H, 3rd and R planetary pinion) 2 ±0.1 1.6
Thickness of thrust washer
37 3 ±0.1 2.4
(2nd, 1st planetary pinion)
Location Standard clearance Clearance limit
H gear
0.30 – 0.80 1.5
train
3rd gear
0.30 – 0.80 1.5
train Replacement of
Side clearance
38 R gear thrust washer
of planetary pinion 0.30 – 0.80 1.5
train or carrier
2nd gear
0.30 – 0.80 1.5
train
1st gear
0.30 – 0.80 1.5
train
Stepped-type wear of seal ring Standard size Amount of wear
39
mating surface — Max 0.05
Replace
Contact surface of Standard size Amount of wear
40
output shaft oil seal 120 119.8
Clutch Standard Tolerance Standard Clearance
No. size Shaft Hole clearance limit
H –0.5 +0.097 0.5 –
430 0.88
(outside) –0.7 +0.097 0.797
H –0.135 +0.097 0.135 –
405 0.36 In case there is
(inside) –0.232 +0.097 0.329
damage on the
L and 4th –0.5 +0.081 0.5 – surface such as
275 0.86
(outside) –0.7 +0.097 0.781 streaks by sei-
L and 4th –0.110 +0.081 0.110 – zure, but the
255 0.30
(Middle) –0.191 +0.097 0.272 clearance can
Clearance between L and 4th –0.5 +0.063 0.5 – be maintained
41 175 0.84
cylinder and piston (inside) –0.7 +0.097 0.763 within the spec-
ified limit after
3rd, R, the repair, the
2nd –0.5 +0.063 0.5 – parts can be
430 0.87
and 1st –0.7 +0.097 0.763 reused.
(outside) Replace if dam-
3rd –0.125 +0.089 0.125 – aged severely.
395 0.33
(inside) –0.214 +0.097 0.303
R and 1st –0.125 +0.089 0.125 –
380 0.33
(inside) –0.214 +0.097 0.303
2nd –0.125 +0.089 0.125 –
375 0.33
(inside) –0.214 +0.097 0.303
HD465-7R, HD605-7R 25
Disc clutch
Structure Operation
When clutch is "engaged" (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through oil the passage
return spring (6) and washer (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is "disengaged" (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
q Washer spring (8) is installed between plate (3)
of the pin block and plate (3). This spring
quickens return of piston (2) as the clutch is
disengaged by providing smooth separation of
plate (3) and disc (4). At the same time, it is
used for preventing the dragging.
26 HD465-7R, HD605-7R
Power transmitting route

Forward 1st speed
L ring gear (2) of the L clutch and 1st ring gear (3) of the 1st clutch are fixed hydraulically.
Power from torque converter o (From left bottom)

O O
Input shaft (1) Intermediate shaft (8)
O O
H carrier (4) 1st planetary pinion (9)
O O
L ring gear (2) 1st, 2nd carrier (10)
O O
H ring gear (5) Output shaft (24)
O
L clutch housing (7)
O
(To right top) o
HD465-7R, HD605-7R 27
Forward 2nd speed
L ring gear (2) of the L clutch and 2nd ring gear (13) of the 2nd clutch are fixed hydraulically.

O O
O O
H carrier (4) 2nd sun gear (11)
O O
L ring gear (2) 2nd planetary pinion (12)
O O
H ring gear (5) 1st, 2nd carrier (10)
O O
L clutch housing (7) Output shaft (24)
O
(To right top) o
28 HD465-7R, HD605-7R
Forward 3rd speed
H sun gear (14) of the H clutch and 2nd ring gear (13) of the 2nd clutch are fixed hydraulically.

O O
O O
H carrier (4) 2nd sun gear (11)
O O
H planetary pinion (6) 2nd planetary pinion (12)
O O
H ring gear (5) 1st, 2nd carrier (10)
O O
L clutch housing (7) Output shaft (24)
O
(To right top) o
HD465-7R, HD605-7R 29
Forward 4th speed
L ring gear (2) of the L clutch and 3rd ring gear (15) of the 3rd clutch are fixed hydraulically.

O O
Input shaft (1) Intermediate shaft (8) ––o
O O O
H carrier (4) 3rd sun gear (16) O
O O O
L ring gear (2) 3rd planetary pinion (17) O
O O O
H ring gear (5) 3rd, R carrier (18) O
O O O
L clutch housing (7) 2nd ring gear (13) 2nd sun gear (11)
O O O
(To right top) o 2nd planetary pinion (12) i––
O
1st, 2nd carrier (10)
O
Output shaft (24)
30 HD465-7R, HD605-7R
Forward 5th speed
H sun gear (14) of the H clutch and 3rd ring gear (15) of the 3rd clutch are fixed hydraulically.

O O
O O O
H carrier (4) 3rd sun gear (16) O
O O O
H planetary pinion (6) 3rd planetary pinion (17) O
O O O
H ring gear (5) 3rd, R carrier (18) O
O O O
L clutch housing (7) 2nd ring gear (13) 2nd sun gear (11)
O O O
(To right top) o 2nd planetary pinion (12) i––
O
O
Output shaft (24)
HD465-7R, HD605-7R 31
Forward 6th speed
L ring gear (2) of the L clutch and 4th clutch drum (19) of the 4th clutch are fixed hydraulically.

O O
O O O
H carrier (4) 4th clutch housing (21) O
O O O
L ring gear (2) 4th clutch drum (19) O
O O O
H ring gear (5) 4th ring gear (20) O
O O O
L clutch housing (7) 3rd, R carrier (18) O
O O O
(To right top) o 2nd ring gear (13) 2nd sun gear (11)
O O
2nd planetary pinion (12) i––
O
O
Output shaft (24)
32 HD465-7R, HD605-7R
Forward 7th speed
H sun gear (14) of the H clutch and 4th clutch drum (19) of the 4th clutch are fixed hydraulically.

O O
O O O
H carrier (4) 4th clutch housing (21) O
O O O
H planetary pinion (6) 4th clutch drum (19) O
O O O
H ring gear (5) 4th ring gear (20) O
O O O
L clutch housing (7) 3rd, R carrier (18) O
O O O
(To right top) o 2nd ring gear (13) 2nd sun gear (11)
O O
2nd planetary pinion (12) i––
O
O
Output shaft (24)
HD465-7R, HD605-7R 33
Reverse 1st speed
L ring gear (2) of the L clutch and R ring gear (21) of the R clutch are fixed hydraulically.

O O
O O
H carrier (4) R sun gear (22) i––
O O I
L ring gear (2) R planetary pinion (23) Intermediate shaft (8)
O O I
H ring gear (5) 3rd, R carrier (18) I
O (R ring gear (21) is fixed with R I
L clutch housing (7) clutch = 3rd, R carrier (18) is I
O rotated reverse to input shaft (1)) I
(To right top) o O I
2nd ring gear (13) 2nd sun gear (11)
O I
2nd planetary pinion (12) ––o
O
O
Output shaft (24)
34 HD465-7R, HD605-7R
Transmission control valve 1
A: H clutch oil pressure pickup port Operation table of ECMV

B: Lockup clutch oil pressure pickup port ECMV
C: L clutch oil pressure pickup port sgear L H 1st 2nd 3rd 4th R L/U
D: 4th clutch oil pressure pickup port speed
E: 3rd clutch oil pressure pickup port
F1 Q Q Q
F: R clutch oil pressure pickup port
G: 2nd clutch oil pressure pickup port F2 Q Q Q
H: 1st clutch oil pressure pickup port F3 Q Q Q
J: To breather F4 Q Q Q
K: To main pressure variable valve
F5 Q Q Q
1. H clutch ECMV F6 Q Q Q
2. Lockup clutch ECMV F7 Q Q Q
3. L clutch ECMV N
4. 4th clutch ECMV
R1 Q Q
5. 3rd clutch ECMV
6. R clutch ECMV L/U: lockup clutch ECMV
7. 2nd clutch ECMV
8. 1st clutch ECMV Outline
9. Last chance filter
q Lockup clutch ECMV operates when traveling
10. Valve seat
forward at the speed higher than the set speed
of transmission controller.
HD465-7R, HD605-7R 35
ECMV 1
For H, L, 4th, 3rd, R, 2nd, 1st clutches
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1: Pressure control valve spool of the unit for H,

P: From pump 3rd, R, 2nd and 1st clutches is different from
T: Drain one for L and 4th clutches.
Dr: Drain *2: Nameplate stamp of the unit for H, 3rd, R, 2nd
P1: Clutch oil pressure pickup port and 1st clutch is different from one for L and
4th clutches.
1. Fill switch connector
Stamp of the name-
2. Proportional solenoid connector Operated clutches
plates
3. Flow detection valve
4. Fill switch H, 3rd, R, 2nd, 1st D*******
5. Proportional solenoid Q*******
L, 4th
6. Pressure control valve (*1)
7. Nameplate (*2)
36 HD465-7R, HD605-7R
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current - propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force - Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “ON“ by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
HD465-7R, HD605-7R 37
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned "OFF".
Range A: Before shifting gear (When draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
38 HD465-7R, HD605-7R
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If a current is given to proportional solenoid (1) q As current is conducted to proportional sole-

while there is no oil in the clutch, a hydraulic noid (1), the solenoid generates thrust in pro-
force balanced with the solenoid force is portion to the current. The pressure is settled
applied to chamber (B) and it pushes pressure as the sum of this thrust of the solenoid, thrust
control valve (3) to the left. This conducts oil generated by the oil pressure in clutch port and
through pump port (P) and orifice (a) of flow the repulsive force of pressure control valve
rate pickup valve (4) to start filling the oil to the spring (2) is balanced.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward. As
the clutch chamber is filled up with oil and oil
flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON“ fill switch (5).
HD465-7R, HD605-7R 39
For lockup clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Stamp of the name-
T: Drain Operated clutches
plates
Dr: Drain
P1: Clutch oil pressure pickup port Lockup K*******
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
40 HD465-7R, HD605-7R
Outline Operation
q This valve is used to switch the clutch in order When traveling in torque converter range
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
At gear shift (in direct travel)

q While no current is flowing in to proportional
solenoid (1), pressure control valve (3) drains
the oil from clutch port (A) through drain port
(T).
HD465-7R, HD605-7R 41
When traveling in direct range

(Torque converter travel o direct travel)
q As current is conducted to proportional sole-

noid (1), the oil pressure being balanced with
the solenoid force is applied to chamber (B),
pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q If the clutch is filled with the oil, the trust of the
solenoid is balanced with the sum of the
hydraulic thrust in the clutch port and the reac-
tion force of pressure control valve spring (2),
thus the pressure is regulated.
42 HD465-7R, HD605-7R

© 2006 KOMATSU
All Rights Reserved
44 HD465-7R, HD605-7R
SEN02293-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Power train system, Part 2
Axle ................................................................................................................................................................. 2
Differential ....................................................................................................................................................... 4
Final drive ....................................................................................................................................................... 5
Wheels ............................................................................................................................................................ 6
HD465-7R, HD605-7R 1
Axle 1
Front
1. Wheel hub
Unit: mm
Repair or
2 Wear of oil seal sliding surface –0.130
280 — replace
–0.130
2 HD465-7R, HD605-7R
Rear
1. Differential Specifications
2. Axle housing Reduction ratio
3. Brake Differential: 3.538
4. Final drive Final drive : 4.737
Oil
Differential: T030-CD (95 liters)
Final drive : T030-CD (32 liters each side)
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
Rim size: 17.00-35
HD465-7R, HD605-7R 3
Differential 1
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: T030-CD (95 liters)
Unit: mm
Wear of oil seal contact sur- Repair or
7 –0.100
face of coupling 150 — replace
–0.100
Thickness of side gear thrust –0.100
8 6 5.5 Replace
washer –0.050
Backlash between bevel gear
9 0.41 – 0.56 Adjust
and pinion
4 HD465-7R, HD605-7R
Final drive 1
1. Sun gear (No. of teeth: 19) Specification

2. Planet gear (No. of teeth: 24) Type: Planetary gear, splash-type lubrication
3. Planet gear shaft Reduction ratio: 4.737
4. Ring gear (No. of teeth: 71) Oil: T030-CD (32 liters each side)
5. Inner hub
6. Wheel hub
7. Drive shaft
Unit: mm
Backlash between planet gear Standard backlash Repair limit
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
HD465-7R, HD605-7R 5
Wheels 1
Front wheel
1. Tire
2. Rim assembly
3. Valve
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
Rear wheel
1. Rim assembly
2. Valve
3. Extension
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
6 HD465-7R, HD605-7R

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R
SEN02294-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Steering system
Steering column .............................................................................................................................................. 2
Steering linkage .............................................................................................................................................. 3
HD465-7R, HD605-7R 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
2 HD465-7R, HD605-7R
Steering linkage 1
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm
HD465-7R, HD605-7R 3
4 HD465-7R, HD605-7R
Unit: mm
Clearance between inner and size Shaft Hole clearance limit
5
outer for knuckle arm bushing
0.150 –
165 0.7
0.300
Clearance between bushing –0.035 +0.054 0–
6 85 0.3
and pin –0.035 +0.054 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
Clearance between inner and 0.120 –
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 +0.054 0.122
bushing
HD465-7R, HD605-7R 5

© 2006 KOMATSU
All Rights Reserved
6 HD465-7R, HD605-7R
SEN02295-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Brake system
Brake piping .................................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Secondary brake valve ................................................................................................................................... 7
Relay valve ..................................................................................................................................................... 8
Front brake off valve ....................................................................................................................................... 9
Accumulator charge valve............................................................................................................................. 10
Accumulator .................................................................................................................................................. 14
Slack adjuster ............................................................................................................................................... 15
Brake............................................................................................................................................................. 17
Parking brake solenoid valve ........................................................................................................................ 21
HD465-7R, HD605-7R 1
Brake piping 1
2 HD465-7R, HD605-7R
1. Front brake OFF valve 7. Accumulator charge valve

2. Relay valve 8. Accumulator (parking brake)
3. Slack adjuster 9. Accumulator (rear brake)
4. Secondary brake valve 10. Accumulator (front brake)
5. Brake valve 11. Proportional reducing valve (for retarder)
6. Parking brake valve 12. Brake system tank
HD465-7R, HD605-7R 3
Brake valve 1
1. Pilot piston A: To rear brake

2. Rod B: To front brake
3. Lower cylinder C: To brake system tank
4. Spool D: From front accumulator
5. Upper cylinder E: From rear accumulator
6. Spool
4 HD465-7R, HD605-7R
Operation Applying brake when upper valve fails

Upper portion • Even if there is leakage of oil in the upper pip-
• When brake pedal (1) is depressed, the operating, spool (5) is moved down mechanically
ing force is transmitted to spool (3) through rod when pedal (1) is depressed, and the lower por-
(2) and spring (4). When spool (3) goes down, tion is actuated normally.
drain port (a) is closed, and the oil from the The upper valve is not actuated.
pump 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 pip-
Lower portion ing, 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
pr e s s ur e b et we en p or t ( A ) an d po r t ( C )
becomes high, the oil entering port (H) from ori-
fice (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 hap-
pens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
HD465-7R, HD605-7R 5
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 • When pedal (1) is released and the operating
shut off, oil also fills the front brake cylinder at force is removed from the top of the spool, the
the same time, so the pressure in the circuit back pressure from the brake cylinder and the
between port (B) and port (D) rises. The oil force of the spool return spring move spool (3)
entering port (J) from orifice (f) of spool (5) up. Drain port (a) is opened and the oil from the
pushes up spool (5) by the same amount that brake cylinder flows to the brake system tank
spool (3) moves, and shuts off port (B) and port return circuit to release the rear brakes.
(D). Drain port (b) is closed, so the oil entering
the brake cylinder is held, and the brake is Lower portion
applied. • When the pedal is released, spool (3) in the
• The pressure in the space in the upper portion upper portion moves up. At the same time, the
is balanced with the operating force of the back pressure from the brake cylinder and the
pedal, and the pressure in the space in the force of the spool return spring move spool (5)
lower portion is balanced with the pressure in up. Drain port (b) is opened and the oil from the
the space in the upper portion. When spools (3) brake cylinder flows to the brake system tank
and (5) move to the end of their stroke, the cir- return circuit to release the front brake.
cuits between ports (A) and (C) and between
ports (B) and (D) are fully opened, so the pres-
sure in the space in the upper and lower por-
tions 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.
6 HD465-7R, HD605-7R
Secondary brake valve 1
1. Rod Function
2. Spool q This valve operates the brake depending on
3. Cylinder the parking brake release pressure controlled
by the secondary brake pedal.
A: To parking brake valve
P: From accumulator
T: To brake system tank
HD465-7R, HD605-7R 7
Relay valve 1
1. Spool Function
2. Upper cylinder q This valve operates the front brake depending
3. Lower cylinder on the parking brake release pressure con-
4. Spool trolled by the secondary brake pedal.
A: To front brake
P: From accumulator
Pp: From secondary brake valve
8 HD465-7R, HD605-7R
Front brake off valve 1
1. Connector Function
2. Solenoid q 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 opera-
P: From brake valve tor's seat is pressed, the solenoid is energized,
T: To brake system tank and the valve cuts off the circuit between the
brake valve and the front brake.
HD465-7R, HD605-7R 9
Accumulator charge valve 1
ACC:To accumulator Specification

P: From hydraulic pump q Cut in pressure: 14.2 MPa {145 kg/cm2}
PP: From accumulator q Cut out pressure: 20.6 MPa {210 kg/cm2}
H1: Relief valve Function
R1: Relief valve
q 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 accu-
mulator.
q 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.
10 HD465-7R, HD605-7R
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
HD465-7R, HD605-7R 11
Operation 2. When oil supplied to accumulator

1. When no oil is being supplied to accumula- 1) Cut-in condition
tor (cut-out condition) q When the pressure at port (B) is lower
q The pressure at port (B) is higher than the set than the set pressure of the relief valve
pressure of the relief valve (R1), so piston (8) (R1), piston (8) is pushed back down by
is forcibly pushed up by the oil pressure at port spring (5).
(B). Poppet (6) is opened, so port (C) and port q Valve seat (7) and poppet (6) are brought
(T) are short circuited. into tight contact, and port (C) and port (T)
q The spring chamber at the right end of spool are shut off.
(15) is connected to port (C) of the relief valve q The spring chamber at the right end of
(R1), so the pressure becomes the brake oil spool (15) is also shut off from port (T), so
tank pressure. The oil from the pump enters the pressure rises, and the pressure at
port (P), pushes spool (15) to the right at a low port (P) also rises in the same way.
pressure equivalent to the load on spring (14). q When the pressure at port (P) goes above
q It also passes through orifices (17), (18) and the pressure at port (B) (accumulator
(16), and flows to the brake oil tank. pressure), the supply of oil to the accumu-
lator starts 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.
12 HD465-7R, HD605-7R
2) When cut-out pressure is reached 3. Main relief valve (R3)

q When the pressure at port (B) (accumula- q If the pressure at port (P) (pump pressure)
tor pressure) reaches the set pressure of goes above the set pressure of the relief valve
the relief valve (R1), poppet (6) separates (R3), the oil from the pump pushes spring (3).
from valve seat (7), so an oil flow is gener- Ball (11) is pushed up and the oil flows to the
ated and the circuit is relieved. brake oil tank circuit, so this set the maximum
q When the circuit is relieved, a pressure pressure in the brake circuit and protects the
difference is generated above and below circuit.
piston (8), so piston (8) moves up, poppet
(6) is forcibly opened, and port (C) and
port (T) are short circuited.
q 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.
q 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.
HD465-7R, HD605-7R 13
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q 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 compressibil-
ity of the gas to absorb the pulse of the hydrau-
lic 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}
14 HD465-7R, HD605-7R
Slack adjuster 1
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
Clearance between body and size Shaft Hole clearance limit
4
piston
–0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Standard size Repair limit Replace
Spring Installed Installed Installed
Free length
5 Slack adjuster spring coefficient length load load
0.45 N/mm 45.6 N
97 — —
{0.046 kg/mm} {4.7 kg}
HD465-7R, HD605-7R 15
Function q If the brake pedal is depressed further, and the

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

q 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.
q 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.
16 HD465-7R, HD605-7R
Brake 1
Front
1. Piston
2. Pad
3. Disc
Unit: mm
Wear of pad (remaining thick- Standard size Repair limit
4
ness of wear material) 19.5 3.0 Replace
5 Missing portion of pad — Ratio of surface: 10%
Correct or
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
Correct
(Note 2)
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.
HD465-7R, HD605-7R 17
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. Piston (for parking brake)
18 HD465-7R, HD605-7R
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 97.9 90.9
HD465-7R, HD605-7R 19
Function Operation of parking brake

q The rear brake is of an oil cooled multiple disc q The parking brake contained in the rear brake
type, and it operates as a parking brake by use is structurally designed to operate mechani-
of spring. cally by spring (8) force and to be released by
hydraulic pressure.
Operation of brake q The parking releasing hydraulic pressure acts
q When the brake pedal is depressed, oil pres- on the parking brake piston (10) from the accu-
sure from the brake valve moves brake piston mulator through the brake valve and parking
(7) to the right in the direction of the arrow. brake solenoid.
This presses disc (5) and plate (4) together q With the parking brake switch at the driver's
and generates friction between the disc and seat in the travel position, the parking releas-
plate. The wheel is rotating together with the ing hydraulic pressure releases the parking
disc, so this friction reduces the travel speed brake by pressing the parking brake piston
and stops the machine. (10) and retracting the spring (8).
q When the brake pedal is released, the pres- q With the parking brake switch in the parking
sure at the back face of brake piston (7) is position, the parking brake solenoid is demag-
released, so the piston is moved to the left in netized and the parking releasing hydraulic
the direction of the arrow by the internal pres- pressure is released. Then, the parking brake
sure, and this releases the brake. is engaged through the parking brake piston
(10), brake piston (7), plate (4), and disk (5)
pressed by spring force.
20 HD465-7R, HD605-7R
Parking brake solenoid valve 1
2. Solenoid q The parking brake solenoid is installed in the
brake oil circuit between the secondary brake
B: To parking brake valve and the rear brake. When the parking
P: From secondary brake valve brake switch is set to PARK, the solenoid valve
T: To brake system tank is demagnetized and cut off the parking brake
release oil pressure. Then, the spring force of
brake will operate the parking brake.
HD465-7R, HD605-7R 21

© 2006 KOMATSU
All Rights Reserved
22 HD465-7R, HD605-7R
SEN02296-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 4
Rear axle support.......................................................................................................................................... 10
HD465-7R, HD605-7R 1
Suspension 1
1. Front suspension cylinder

2. Radius rod (Upper rod)
3. Rear suspension cylinder
4. Radius rod (Lower rod)
5. Arm (A-frame)
Outline gas. This acts as a shock absorber (spring and

q The suspension system supports the weight of damper) by contracting and expanding the
the chassis, and absorbs the shock from nitrogen gas and oil to absorb the load from
uneven road surfaces to provide a comfortable the road surface.
ride for the operator. At the same time, it main- q In addition to these functions, the front suspen-
tains the stability of the machine by ensuring sion employs an automatic suspension sys-
that all four wheels are always in contact with tem. In this system, the force of the suspension
the ground surface. In this way, it allows the is automatically changed by selecting the
machine to demonstrate its full performance in dumping force to match the travel conditions
items such as acceleration, braking, and turn- and load conditions. This further increases the
ing, even when traveling at high speed. stability and riding comfort of the machine.
q Hydropneumatic cylinders are used for the
suspension cylinders to reduce the shock. With
hydropneumatic cylinders, the suspension cyl-
inder is charged (sealed) with oil and nitrogen
2 HD465-7R, HD605-7R
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 stability 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
function to maintain the center of the machine
(axle).
Employment of the inverted-V-shaped link im-
proves the rolling steering characteristics.
HD465-7R, HD605-7R 3
Suspension cylinder 1
Front
1. Feed valve 7. Hydraulic 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
4 HD465-7R, HD605-7R
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit Replace
11
and bushing bushing
–0.043 +0.240 0.103 –
160 0.4
–0.106 +0.006 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 +0.115 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
HD465-7R, HD605-7R 5
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
chamber (B) and oil chamber (C) are conmected by
tube (6) and valve body (8).
a. Nitrogen gas
When the machine is traveling, the wheels fol-
low 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 correspond-
ing 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 ori-
fice plate (8a) is throttled 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 nitro-
gen gas extends the rod, and the oil in oil
chamber (C) passes through tube (6) and
valve (8) and flows to oil chamber (B).
The oil inside the valve flows from direc-
tion (X) and passes through two orifices
from orifice plate (8a) to generate a damp-
ing force.
6 HD465-7R, HD605-7R
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
according 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.
HD465-7R, HD605-7R 7
Rear
1. Feed valve
2. Cylinder
3. Rod
4. Valve (for bleeding air and mounting pressure sensor)
5. Ball
8 HD465-7R, HD605-7R
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
6
and bushing
–0.043 +0.306 0.103 –
180 0.5
–0.106 +0.060 0.412
Replace
Clearance between piston rod –0.043 +0.246 0.043 –
7 180 0.4
and bushing –0.106 +0.246 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 cylinder.
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). 1. Valve (for bleeding 7. Nitrogen gas chamber
This pressurized oil closes orifice (4) with and mounting pres- 8. Cylinder rod
check ball (3), and is sent to chamber (6) sure sensor) 9. Cylinder
through only orifice (5), so the flow of oil pass- 2. Cavity 10. Feed valve
ing through the orifice is controlled so that it is 3. Check ball
less than during retraction. 4. Orifice a: When extending
In this way, the amount of oil returning to 5. Orifice b: When retracting
chamber (6) is restricted to provide a shock 6. Oil chamber
absorbing effect.
HD465-7R, HD605-7R 9
Rear axle support 1
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
10 HD465-7R, HD605-7R
Unit: mm
Clearance between rod mount- size Shaft Hole clearance limit
5
ing pin and bushing
–0.030 +0.046 0.030 –
70 1.0
–0.076 +0.046 0.122
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 +0.046 0.122
frame or axle
8 100 0.5
outer bushing 0.180
HD465-7R, HD605-7R 11

© 2006 KOMATSU
All Rights Reserved
12 HD465-7R, HD605-7R
SEN02297-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Hydraulic system
Steering and hoist hydraulic piping ................................................................................................................. 2
Dump body control.......................................................................................................................................... 4
Hydraulic tank ................................................................................................................................................. 5
Steering valve ................................................................................................................................................. 6
Crossover relief valve ................................................................................................................................... 10
Steering cylinder ............................................................................................................................................11
Steering control valve.................................................................................................................................... 12
Hoist valve .................................................................................................................................................... 18
EPC valve ..................................................................................................................................................... 24
Hoist cylinder ................................................................................................................................................ 25
Hydraulic pump ............................................................................................................................................. 26
HD465-7R, HD605-7R 1
Steering and hoist hydraulic piping 1
2 HD465-7R, HD605-7R
1. Cross-over relief valve

2. Steering cylinder
3. Hydraulic pump (SDR(30)80+80+(1)6)
4. Steering control valve
5. Hoist valve
6. Hoist cylinder
7. Hydraulic tank
8. Steering hoist filter
9. Steering valve
HD465-7R, HD605-7R 3
Dump body control 1
1. Dump lever Function

2. Hydraulic pump (SDR(30)80+80+(1)6) q 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 q 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.
4 HD465-7R, HD605-7R
Hydraulic tank 1
1. Breather
2. Drain
3. Oil level gauge
Capacity: 97 l
HD465-7R, HD605-7R 5
Steering valve 1
1. Input shaft 8. Ball a: From steering control valve

2. Upper cover 9. Torsion bar (P port)
3. Valve spool 10. Link b: To tank (R port)
4. Housing 11. Sleeve c: To steering cylinder (RT port)
5. Ball 12. Rotor d: To steering control valve
6. Stator 13. Manifold (LS port)
7. Lower cover 14. Commutator e: To steering cylinder (LT port)
6 HD465-7R, HD605-7R
Operation
1. When steering is at neutral
q The oil from the pump passes through the

steering control valve and enters port (P) of the
steering valve
q Valve spool (3) is at the neutral position, so
port (P) and the port (RT and LT) to cylinder
are closed. No oil flows to the cylinder, so the
cylinder does not move.
q At the same times, port (LS) is connected
trough port (R) to the tank. As a result, there is
no oil pressure at port (LS), so all the oil from
the pump at the steering control valve flows to
the hoist valve.
HD465-7R, HD605-7R 7
2. Steering to right
(When steering wheel is turned to the right)
q When the steering wheel is turned (to the q The oil returning from the steering cylinder
right), input shaft (1) rotates. When this hap- flows from port (LT) trough port (E) and port (R)
pens, valve spool (3) moves down. (Input shaft and goes back to the tank.
(1) has a spiral groove in which ball (8) moves, q At the same time, the oil pressure at port (P) is
so when input shaft (1) rotates, torsion bar (9) restricted by valve spool (3), and passes
is twisted, and all (8) moves up or down to trough port (A), so a lower oil pressure (the
move valve spool (3).) drop in pressure (pressure difference) differs to
q The oil from the steering control valve flows according to the area of the opening of the
from port (P) through port (A) and port (G) and spool) than the pressure at port (P) is applied
goes to port (F). to port (LS).
q The oil at port (F) then passes between stator q The steering control valve spool is actuated by
(6) and rotor (12) in the metering position. After the difference in pressure between the oil pres-
the amount of oil flowing to steering cylinder is sure at port (P) end and the oil pressure at the
measured here, it enters the inside of valve port (LS) end. As a result, only the necessary
spool (3), passes through hole (a) in the valve amount of oil flows to the steering circuit, and
spool through port (RT) and flows to the steer- remaining oil flows from the steering control
ing cylinder. valve to the hoist valve.
q In this way, the two cylinders are actuated and
the wheels turn to the right.
8 HD465-7R, HD605-7R
3. Steering to left
(When the steering wheel is turned to the left.)
q When steering wheel is turned (to the left), q At the same time, the oil pressure at port (P) is
input shaft (1) rotates. When this happens, restricted by valve spool (3), so a lower oil
valve spool (3) moves up. pressure than the pressure at port (P) is
q The oil from the steering control valve flows applied to port (LS).
from port (P) enters port (B) passes trough q The steering control valve spool is actuated by
hole (a) in valve spool (3), and enters the the difference in pressure between the oil pres-
inside of the valve spool. sure at port (P) end and the oil pressure at the
q The oil inside valve spool (3) passes between port (LS) end. As a result, only the necessary
stator (6) and rotor (12) in metering portion. amount of oil flows to steering circuit, and
After the amount of oil flowing to the steering remaining oil flows from the steering control
cylinder is measured here, it flows to port (F). valve to the hoist circuit.
q The oil at port (F) passes trough port (LT) and
flows to steering cylinder.
q In this way, the two cylinders are actuated and
the wheels turn to the left.
q The oil returning from the steering cylinder
flows from port (RT) trough port (D) and port
(R) and goes back to the tank.
HD465-7R, HD605-7R 9
Crossover relief valve 1
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 HD465-7R, HD605-7R
Steering cylinder 1
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit 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 +0.039
Clearance between cylinder Replace
+0.039
3 bottom support shaft and bush- 45 — — 1.0
+0.039
ing
HD465-7R, HD605-7R 11
Steering control valve 1
12 HD465-7R, HD605-7R
P1: From hydraulic pump

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

2. Steering control valve 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 Installed Installed Installed
Free length
12 Spool return spring x O.D length load load
213.6 x 363.6 N 342.0 N Replace
140 —
32.5 {37.1 kg} {34.9 kg}
3.4 N 3.1 N
13 Check valve spring 42.2 x 17 33.5 —
{0.345 kg} {0.315 kg}
HD465-7R, HD605-7R 13
Function
q The steering control valve acts to divide the oil
sent from the steering pump and the hoist
pump for the work equipment, and sends it to
the steering circuit and hoist circuit according
to the pressure signal from the steering valve.
q Steering control valve is a load sensing type
and is controlled the steering control valve
spool according to the operation of steering. In
other words, if the steering is not being oper-
ated (when no oil is needed in the steering cir-
cuit), the steering control valve sends all the oil
from the pump to the hoist valve. When the
steering circuit is operated the amount of oil
needed for steering is sent to the steering cir-
cuit, and the rest is sent to the hoist valve. In
this way, the hydraulic power loss in the steer-
ing circuit is reduced.
Operation
1. When steering valve is at neutral.
The oil from the steering pump enters port (A).
At the same times, the oil from the hoist pump
enters port (B). When the steering valve is at
neutral, port (P) of the steering valve is closed,
so the pressure at port (P) rises. The pressure
from port (P) passes through orifice (a), enters
the chamber (C), and moves spool (2) to the
right.
Port (LS) and chamber (D) are connected to
the tank, and the force moving spool (2) to the
left is only the force of spool return spring (1).
The pressure in chamber (C) rises until it over-
comes the set pressure of spool return spring
(1). As a result , spool (2) stops in the position
shown in diagram on the right, and all the oil
from the steering pump and hoist pump flows
to the hoist valve.
14 HD465-7R, HD605-7R
2. When steering valve is operated.

When the steering is operated, port (P) and
port (LS) are connected, and the circuit
between the tank and port (LS) is shut off. The
hydraulic pressure before entering the orifice
of the steering control valve acts on chamber
(C) of spool (2), and the hydraulic pressure
coming out from the orifice acts on chamber
(D).
There is a difference in the area of the opening
of the steering control valve orifice when the
steering is turned quickly and when it is turned
slowly. Therefore, the hydraulic pressure on
both sides of the orifice also changes and a
pressure difference is created. In this way,
spool (2) is actuated by the balance of the
force of return spring (1) and the differential
pressure between both sides of the orifice. In
other words, it moves according to the balance
of the oil in chamber (C) pushing to the right,
and the force of the oil in chamber (D) pushing
to left + return spring (1). The larger the differ-
ence in pressure at the orifice is, the more
spool (2) moves to the right.
(1) When steering wheel is operated quickly

The area of opening of the steering control
valve orifice is large, so the difference in
pressure between the two sides of the ori-
fice is small. As a result, spool (2) only
moves a short distance to the right, and all
the oil from the steering pump together
with some of the oil from the hoist pump
passes through check valve (3) and flows
to steeri ng valv e to prov ide a lar ge
amount of oil to the steering valve.
HD465-7R, HD605-7R 15
(2) When steering wheel is operated slowly

The area of opening of the steering control
valve orifice is small, so the difference in
pressure between the two sides of the ori-
fice is large. As a result, the movement to
the right increases, and all some of oil
from the steering pump flows to the steer-
ing valve. The remaining oil from the
steering pump and all the oil from the hoist
pump flows to the hoist valve.
16 HD465-7R, HD605-7R
Steering relief valve q When the pressures in port (A) and port (B)
balance with the poppet spring force (set pres-
sure), the pilot poppet (3) will open. Oil in port
(B) will escape through port (D) to port (C), and
the pressure in port (B) will lower.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw q When the pressure in port (B) lowers, the ori-
fice of the main valve (1) generates a differen-
Function tial pressure between ports (A) and (B), and
the pressure in port (A) pushes to opens the
q This valve is located in the steering control
main valve (1) to release oil from port (A).
valve and release oil from the pump to prevent
the pump from being damaged when the steer-
ing cylinder comes to the stroke end, or when
an abnormal pressure occurs. (This valve sets
the maximum pressure of the circuit.)
Operation
q Port (A) is connected to the pump circuit, and
port (C) is connected to the tank drain circuit.
q Oil flows through the orifice of the main valve
(1), and port (B) is filled with oil.
q Also, the pilot poppet (3) is seated to the valve
seat (2).
HD465-7R, HD605-7R 17
Hoist valve 1
18 HD465-7R, HD605-7R
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 Installed Installed
Free length
12 Relief valve poppet spring x O.D. length load load
259 N 233 N
49.3 x 12.8 41.9 —
{26.4 kg} {23.8 kg}
If damaged or
44 N 40 N
13 Check valve spring 32.6 x 10.9 24.5 — deformated,
{4.5 kg} {4.1 kg}
replace the
156 N 140 N spring
14 Spool return spring (lifting) 51.3 x 34.5 50 —
{15.9 kg} {14.3 kg}
124 N 112 N
15 Spool return spring (lowering) 34.2 x 28.7 32 —
{12.7 kg} {11.4 kg}
927 N 849 N
16 Spool return spring (floating) 74.0 x 36.0 55.5 —
{94.5 kg} {85.1 kg}
HD465-7R, HD605-7R 19
Operation
1. Hoist valve HOLD position
q Oil from the steering control valve flows into q Since both the bottom side port and the head
chamber (C). Since the hoist spool (2) blocks side port of the hoist cylinder are blocked, the
the path to the hoist cylinder, oil flows through hoist cylinder is locked where it is.
chamber (D) to the tank.
20 HD465-7R, HD605-7R
2. Hoist valve at LIFT position
q When the hoist lever in the cab is set to the q Oil flows out of chamber (A), flows in the bot-
RAISE position, pressurized oil from the sole- tom side of the hoist cylinder, extends the hoist
noid valve pushes the hoist spool (2) to the left. cylinder and raise the body.
q Therefore, oil from chamber (C) opens the q On the other hand, the return oil from the head
check valve (11) and flows into chamber (A). side flows out of chamber (B), flows into cham-
ber (D) and to the tank circuit.
HD465-7R, HD605-7R 21
3. Hoist valve at FLOAT position
q When the hoist lever in the cab is set to the q Since the bottom side and the head side of the
FLOAT position, pressurized oil from the sole- hoist cylinder are connected through the hoist
noid valve pushes the hoist spool (2) to the valve, the hoist cylinder is in a free state.
right. Then, chambers (C), (D), (B), (H) and
(D) are all connected.
q Oil from the steering control valve flows from
chamber (C) through chamber (B) to the host
cylinder and from chamber (C) through cham-
ber (D) to the oil cooler circuit.
22 HD465-7R, HD605-7R
4. Hoist valve at LOWER position
q When the hoist lever in the cab is set from the q On the other hand, the return oil from the head
FLOAT position to the LOWER position, pres- side of the hoist cylinder flows out of chamber
surized oil from the solenoid valve pushes the (A) and flows into chamber (H).
hoist spool (2) to the right further from the q At the time of lowering, the output pressure of
FLOAT position. Therefore, oil from chamber the solenoid valve rises over the cracking pres-
(C) pushes to open the check valve (11) and sure of the pilot check valve, and therefore, the
flows into chamber (B). return oil from chamber (H) returns through
q Then, oil flows into the head side of the hoist chamber (D) to the tank.
cylinder through chamber (B), retracts the hoist
cylinder and lowers the body.
HD465-7R, HD605-7R 23
EPC valve 1
1. Manual operation button Function

2. Solenoid assembly q The EPC valve controlled by the retarder con-
3. Solenoid assembly troller switches the pilot pressure of the hoist
valve, and controls pressure, and controls the
A: To hoist valve hoist valve.
B: From hoist valve
T1: To hydraulic tank
T2: To hydraulic tank
24 HD465-7R, HD605-7R
Hoist cylinder 1
Unit: mm
Clearance between cylinder and size Shaft Hole clearance limit
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
HD465-7R, HD605-7R 25
Hydraulic pump 1
Steering, hoist and hoist control pump
SDR(30)80+80+SB(1)6
Unit: mm
Model Standard clearance Clearance limit
SDR(30)-80
1 Side clearance 0.16 – 0.20 0.24
SDR(30)-80
SBR(1)-6 0.10 – 0.15 0.19
Clearance between inside SDR(30)-80
diameter of plain bearing and 0.06 – 0.131 0.20
2 SDR(30)-80 Replace
outside of diameter of gear
shaft SBR(1)-6 0.06 – 0.119 0.20
Model Standard size Tolerance Repair limit
SDR(30)-80 –0.5
3 Depth to knock in pin 10
SDR(30)-80 –0.5 —
SBR(1)-6 9.1 ± 0.3
4 Rotating torque of spline shaft 15.8 – 28.5 Nm {1.6 – 2.9 kgm}
Standard
Rotating Delivery Delivery
delivery
Model speed pressure amount limit
amount
Discharge amount (rpm) MPa {kg/cm2} ( /min)
( /min) —
— Oil: EO10-CD
Oil temperature: 45–55°C SDR(30)-80
184.5 170.4
SDR(30)-80 2,500 20.6 {210}
SBR(1)-6 13.8 12.6
26 HD465-7R, HD605-7R
Retarder cooling pump

SDR(30)100+100
Unit: mm
Clearance between gear case Model Standard clearance Clearance limit
1
and side plate, gear SDR(30)-100 0.16 – 0.20 0.24
Clearance between inside
2 diameter of plain bearing and SDR(30)-100 0.06 – 0.131 0.20
outside diameter of gear shaft Replace
3 Depth to knock in pin –0.5
SDR(30)-100 10 —
–0.5
4 Rotating torque of splined shaft 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
Standard Delivery
Rotating
Delivery delivery amount
Delivery amount Model speed
pressure amount limit
— Oil: EO10-CD (rpm) —
( /min.) ( /min.)
Oil temperature: 45 – 55°C
20.6 MPa
SDR(30)-100 2,500 230.9 213.4
{210 kg/cm2}
HD465-7R, HD605-7R 27
Torque converter, transmission, retarder cooling and brake pump

SDR(30)100+SA(1)25
Unit: mm
1 Side clearance SDR(30)-100 0.16 – 0.20 0.24
SAR(1)-25 0.10 – 0.15 0.20
Clearance between inside SDR(30)-100 0.06 – 0.131
diameter of plain bearing and
2 0.20 Replace
outside of diameter of gear SAR(1)-25 0.06 – 0.119
shaft
Model Standard size Tolerance
3
Depth to knock in pin SDR(30)-100 –0.5
10 —
4 SAR(1)-25 –0.5
5 Rotating torque of spline shaft 8.9 – 16.7 Nm {0.9 – 1.7 kgm}
Delivery Standard Delivery
Rotating pressure delivery amount
Model speed MPa
Discharge amount amount limit —
(rpm)
— Oil: EO10-CD {kg/cm2} ( /min) ( /min)
Oil temperature: 45–55°C
SDR(30)-100 20.6 {210} 230.9 213.4
2,500
SAR(1)-25 24.5 {250} 56.5 50.8
28 HD465-7R, HD605-7R
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 –0.5
SBL(1)-014 10 —
–0.5
4 Rotating torque of splined shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Standard Delivery
Rotating
Delivery delivery amount
Delivery amount Model speed
pressure amount limit
— 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}
HD465-7R, HD605-7R 29

© 2006 KOMATSU
All Rights Reserved
30 HD465-7R, HD605-7R
SEN02298-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Cab and its attachments
Air conditioner ................................................................................................................................................. 2
HD465-7R, HD605-7R 1
Air conditioner 1
1. Receiver dryer Heating

2. Air conditioner unit q Heating is carried out using the coolant from
3. Compressor the engine.
4. Condenser High-temperature coolant from the hot water
5. Hot water return port take-off port flows to the air conditioner unit,
6. Hot water take-off port 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
q The air conditioner makes a pleasant operating q The refrigerant gas compressed and pressur-
environment for the operator and acts to ized by the air conditioner compressor enters
reduce fatigue. the air conditioner condenser where it is
cooled by dissipating the heat It then enters
the air conditioner unit and cold air is blown out
by the fan. When the temperature of the refrig-
erant gas rises, it is returned to the compres-
sor.
2 HD465-7R, HD605-7R
Refrigerant flow system
HD465-7R, HD605-7R 3
Air conditioner unit
1. Hot water outlet port

2. Hot water inlet port
3. Refrigerant gas inlet side
4. Refrigerant gas outlet side
4 HD465-7R, HD605-7R
Receiver dryer
1. Sight glass
A: Refrigerant gas inlet port

B: Refrigerant gas outlet port
HD465-7R, HD605-7R 5
Condenser
1. Fin
2. Tube
A: Refrigerant gas inlet port

B: Refrigerant gas outlet port
6 HD465-7R, HD605-7R
Compressor
1. Case
2. Clutch
A: Suction service valve

B: Discharge service valve
HD465-7R, HD605-7R 7

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R
SEN02299-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HD465-7R, HD605-7R 1
Machine monitor system 1
Network data
1. From machine monitor to each controller
q Switch input data
q Option setting data
2. From each controller to machine monitor
q Display data related to each controller
q Service mode data
q Troubleshooting data
3. From transmission controller to machine monitor
q Model selection data
2 HD465-7R, HD605-7R
Outline 2. Displaying trouble history data for ma-

The machine monitor system is comprised of chine
controllers and a machine monitor. The con- Displays machine failure occurrence data
trollers on the network use the data from the from each controller that is saved in
sensors installed to all parts of the machine to machine monitor.
observe and control the condition of the vehi- 3. Real-time monitor
cle and transmit those data as network data to Takes input, output signal, and calculation
the machine monitor. The machine monitor, in values recognized by each controller on
return, displays these data and inform the network and displays them in real time.
operator of the condition of the machine. 4. Reduced cylinder mode
q There are two types of display on the machine This function is used to stop the supply of
monitor: the normal mode and the service fuel sprayed from the fuel injector to each
mode. of the cylinders. This function is used for
q The items that are always displayed for the the purpose of, for example, determining
operator are the normal mode items. Their the cylinder where there is defective com-
main content is as follows. bustion.
1. Normal display items 5. No injection cranking
q Meters (speedometer, tachometer) This function is used to lubricate an
q Gauges (engine coolant tempera- engine without starting the engine to drive
ture, torque converter oil temperature, a vehicle after a long-term storage.
retarder oil temperature, fuel level) 6. Adjusting function
q Pilot display This function is used to correct installation
q Service meter, odometer (character errors of sensors, solenoid valves, and
display) compensate production tolerances of
2. Items displayed when there is abnormality parts and components. This function is
Caution, action code display (while an also used to change control characteristic
action code is being displayed, press data in response to user's request.
machine monitor mode selector switch (>). 7. Maintenance monitor
A failure code (6-digit) is then displayed.) This function is used to change filter oil
replacement interval and stop the func-
3. Maintenance monitor function
tion.
When the filter, oil replacement interval is
8. Operation information display function
reached, the item needing replacement is
This function is used to display fuel con-
displayed in the character display.
sumption amount per operation hour.
4. Others 9. Engine mode fixing function
In combination with the character display This function is used to check the perfor-
and the machine monitor mode selector mance.
switch, which is used to operate the char- 10. Snapshot function
acter display, the following items can be For details of this function, see "Structure,
displayed, set, and adjusted. function and maintenance standard" of
1) Dozing counter (option) "Manual snapshot".
2) Display reverse travel distance mea- 11. Payload meter function (if equipped)
surement value This function is used to setting and adjust-
3) Reset filter oil replacement interval ing of payload meter.
4) Input telephone number For details of this function, see "Operation
5) Select language and maintenance manual" or "Structure,
6) Payload meter calibration ID setting function and maintenance standard" of
(if equipped) "Payload meter (having VHMS)".
q To make it easier to carry out troubleshooting 12. Option selection function
of the controllers on the network (including the This function is used to select controller
monitor panel itself), a service mode function is information and optional equipment to be
provided. Its main content is as follows. operated.
1. Displaying trouble history data for electri- 13. Model selection function
cal components Input model information to be mounted.
q Displays electrical component failure 14. Initialize
occurrence data from each controller This function is used to set the machine
that is saved in machine monitor. monitor when the machine is shipped from
q Deletes data from memory the factory.
HD465-7R, HD605-7R 3
Machine monitor
1. Speedometer 26. Emergency steering pilot lamp

2. Engine tachometer 27. Turn signal pilot lamp (right)
3. Retarder oil temperature gauge 28. Turn signal pilot lamp (left)
4. Torque converter oil temperature gauge 29. Head lamp high beam pilot lamp
5. Coolant temperature gauge 30. Shift lever position pilot lamp
6. Fuel gauge 31. Shift indicator
7. Character display 32. Retarder pilot lamp
8. Centralized warning lamp 33. Lockup pilot lamp
9. Retarder oil temperature caution lamp 34. Output mode pilot lamp (power mode)
10. Torque converter oil temperature caution lamp 35. Output mode pilot lamp (economy mode)
11. Coolant temperature caution lamp 36. Suspension mode pilot lamp (hard)
12. Fuel level caution lamp (if equipped)
13. Maintenance caution lamp 37. Suspension mode pilot lamp (medium)
14. Battery charging circuit caution lamp (if equipped)
15. Steering oil temperature caution lamp 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 (if equipped)
21. Transmission system caution lamp 43. Automatic retarder set speed indicator
22. Retarder system caution lamp (if equipped)
23. Inclination caution lamp 44. Automatic retarder set speed unit indicator (km/
24. Seat belt caution lamp h) (if equipped)
25. Body caution lamp 45. Automatic retarder set speed unit indicator
(MPH) (if equipped)
4 HD465-7R, HD605-7R
46. Rotary switch [SW1] a When setting, follow the instruction in Testing
47. Rotary switch [SW2] and adjusting, Adjusting machine monitor, and
48. Rotary switch [SW3] do not change them.
49. Dipswitch [SW5-4] a When moving the switches, use a precision
50. Dipswitch [SW5-3] screwdriver and turn slowly.
51. Dipswitch [SW5-2] a Be careful not to touch anything except the
52. SI Spec, Non-SI Spec selection switch [SW5-1] switches inside the grommet.
53. Dipswitch [SW6-4] a Be careful not to let any dirt or dust get in.
54. Dipswitch [SW6-3] a After completing the setting, return the grom-
55. Dipswitch [SW6-2] met securely to its original position.
56. Dipswitch [SW6-1]
HD465-7R, HD605-7R 5
Machine monitor normal display functions

: Lighted up : Discontinuous sounds
A1: The mark shows that the light is lit up while the machine monitor check switch is ON.
A2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
Related A1
operation When A2
machine Immedi-
Display Display Display range/ Display Central monitor ately
No. item category Device Color conditions method Remarks
warn- Alarm check after
ing buzzer switch is turning
lamp oper- key ON.
ated.
Note: When machine

monitor check
Scale: switch is oper-
white 0 – 80 km/h or ated, pointer
Move- Back- 0 – 50 MPH Analog starts at current
Meter ment ground (MPH is dis- display — — — position and
played when (Note)
1 Machine color: moves around
speed black non-SI is used.) indication range
and then returns
to starting point.
When the
Backlight LED Amber small lamp is Lit up during — —
lit up. operation
Analog display Note: When machine

monitor check
Scale: * When the switch is oper-
white, red overrun pre- ated, pointer
Move- Back- vention brake starts at current
Meter 0 – 3,400 rpm is operated, —
ment ground (Note) position and
Engine color: the buzzer and moves around
2 speed central warn-
black indication range
ing lamp are and then returns
turned ON. to starting point.
When the Lit up during

Backlight LED Amber small lamp is operation — —
lit up.
Note: When machine

monitor check
white, red 50 – 150°C ated, pointer
Gauge Move- Back- (120°C or higher Analog — — — starts at current
ment ground in the red zone) display (Note) position and
Oil tem- color: moves around
3 perature black indication range
9 of and then returns
retarder to starting point.
Caution LED Red At 120°C Lit up during

or higher warning
When the
lit up. operation.
Note: When machine

monitor check
white, red ated, pointer
Move- Back- 50 – 135°C Analog starts at current
Gauge ment ground (120°C or higher display — — — position and
Oil tem- color: in the red zone) (Note)
moves around
black
4 perature indication range
of torque and then returns
10 con- to starting point.
verter
At 120°C Lit up during
Caution LED Red or higher warning
When the
lit up. operation.
6 HD465-7R, HD605-7R
Related When
operation machine Immedi-
Display Display Display range/ Display monitor ately
No. item category Device Color conditions method check after Remarks
Central switch is turning
warn- Alarm oper-
ing buzzer ated. key ON.
lamp
Note: When machine
monitor check
white, red 50 – 135°C ated, pointer
Gauge Move- Back- (102°C or higher Analog — — — starts at current
ment ground in the red zone) display (Note) position and
Coolant color: moves around
5 temper- black indication range
11 ature and then returns
to starting point.
At 102°C or Lit up during
Caution LED Red higher warning
When the
lit up. operation.
Note: When machine

monitor check
white, red ated, pointer
Move- Back- Analog starts at current
Gauge ment ground EMPTY – FULL display — — — position and
(Note)
color: moves around
black indication range
6 Fuel and then returns
12 level to starting point.
Specified level
Caution LED Red or less Lit up during — —
(At 76 z or operation
higher)
Backlight LED Amber When the small Lit up during — —

lamp is lit up. operation.
Service 0 – 65535.0h Operates
meter when the
(Regu- Service * Displayed in engine is
When 65535.0h is
the "upper col- — — exceeded, fixed at
lar dis- meter running. 65535.0h.
play umn" on the 1:1 against
item) character display clock time
Odome- 0 – 999999.9 km
ter
(Regu- Odometer * Displayed in Operates dur- When 999999.9 km is
the "lower col- — — exceeded, fixed at
lar dis- ing traveling. 999999.9 km.
play umn" on the
item) character display
When any
problem or
When any prob- failure occurs,
Display lem or failure the action
code is dis- Note 1:"KOMATSU" is
charac- occurs on the displayed in the
ter: played in the
Action Action machine, * Dis- upper col- — — Note 1 Note 2 upper column.
7 code code LCD black played in the Note 2:"Program No." is
Back- umn and rem-
upper and lower edies or displayed in the
ground columns on the lower column.
color: character display. description of
green problem in
the lower col-
umn.
The failure
Press machine code
monitor mode (6 digits) and
selector switch > detection
during the occur- controller are
rence of the displayed in For information on how
Failure Failure problem or the upper col- to operate display, see
code code failure on the umn and the — — the Operation & Main-
machine. faulty system tenance Manual.
* Appears in the or descrip-
upper and lower tion of prob-
columns on the lem in the
character display. lower
column.
HD465-7R, HD605-7R 7
Related When
Central Warn- switch is turning
warning oper- key ON.
ing buzzer ated.
lamp
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
When the down by a
Night Backlight LED Green small lamp is step when the — —
lighting lit up. small lamp is
lit up.
Central
8 warning LED Red During system Lit up when
lamp is abnormal abnormal.
Note 1:The moment

when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
nance-related has been given
Mainte- alarm is given or Lit up or appear on the
13 nance LED Red the time to flashed — — character
caution 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 when
14 LED Red charging circuit
circuit abnormal.
being abnormal
caution
Steer-
When the
ing oil
steering oil Lit up when
15 tempera- Caution LED Red
temperature abnormal.
ture
rises.
caution
Engine
When the engine
oil pres- Lit up when
16 LED Red oil pressure
sure abnormal.
drops.
caution
Retarder When the
Operates when the
oil pres- retarder Lit up when
17 LED Red alternator R terminal is
sure oil pressure abnormal. (Note) (Note) ON.
caution 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)
caution operated. is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up when tions, used in the event
19 LED Red machine moni-
optional abnormal. of failure of the
tor or optional
system machine monitor.
controller system
caution
During being
Engine
abnormal in Lit up when
20 system LED Red
engine control abnormal.
caution
system.
8 HD465-7R, HD605-7R
Related When
ing buzzer ated.
lamp
Trans-
When transmis-
mission Lit up when
21
system
LED Red sion control sys-
abnormal.
tem is abnormal
caution
Retarder When retarder
Lit up when
22 system LED Red control system is
abnormal.
caution abnormal
When the body is
Inclina-
lifted and inclined Lit up when
23 tion LED Red
excessively abnormal.
caution
from side to side.
Caution
During
operation:
Seat- When the seat-
lit up
24 belt LED Red belt is not — —
During non-
caution fastened.
operation:
turned OFF.
During
See the operation: Note: Operates when
Body lit up the shift lever is in
25 LED Red instruction
caution manual During non- (Note) (Note) other than the "N"
operation: position.
turned OFF.
During
operation:
Emer- When the emer- lit up
26 gency LED Red gency steering is During non- — —
steering operated. 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 position tral safety is operated.
6
Shift
30 When the shift
lever
5
HD465-7R, HD605-7R 9
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
Shift
30 When the shift
lever
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
When lockup of During
the torque con- operation:
verter is acti- lit up
33 Lockup LED Green — —
vated During non-
and direct drive operation:
is effective turned OFF
High-power
mode
Output
in operation:
mode Pilot At high-power
34 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
Suspen-
sion mode At suspension Lit up in
36 LED Green — —
(hard) (if "hard" mode "hard" mode
equipped)
10 HD465-7R, HD605-7R
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
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-
engine is
operation:
Pilot operated.
turned OFF
Auto-
matic When auto- When ready
retarder matic retarder is to be
42 LED Green — —
being ready to be oper- operated:
ready (if ated. lit up
equipped)
Auto-
matic Back-
retarder ground When automatic Display of set * Zero is displayed
43 LCD retarder switch is — — when the set speed
set speed color:
turned ON. speed (*)
(if gray is cancelled.
equipped)
Auto-
matic During
When automatic
retarder operation:
retarder switch is
unit lit up
44 LED Green turned ON and — —
display During non-
the unit km/h is
(km/h) operation:
selected.
(if turned OFF
equipped)
auto-
During
matic When automatic
operation:
retarder retarder switch is
lit up
45 display LED Green turned on and — —
During non-
unit the unit MPH is
operation:
(MPH) (if selected.
turned OFF
equipped)
HD465-7R, HD605-7R 11
Self-diagnostic function when starting switch is

operated
1. When the starting switch is turned to the ON
position before starting the engine, the system
check is carried out for 3 seconds.
2. If the starting switch is turned to the START
position before 3 seconds have passed with
the starting switch at the ON position, every-
thing will go to the normal operating condition.
However, even if everything goes to the normal
operating condition, the indicator gauges and
meters will not work until 3 seconds have
passed after the starting switch is 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 "Machine monitor normal display
functions when machine monitor check switch is
operated".
12 HD465-7R, HD605-7R
Service mode functions 2) ID input procedure

(1) Press switches </> to increase or
Outline
decrees the value at the cursor posi-
To make it easier to carry out troubleshooting of the tion. Use these switches to select a
controllers on the network (including the monitor desired value and the press switch
panel itself), a service mode function is provided. U.
To initialize sensors, operation settings, and the (2) Repeat the above operation (1) for
like, enter into the service mode of the machine four digits. The electrical equipment
monitor. system failure history screen is dis-
played.
How to operate the machine monitor a When an incorrect value is
1. Enter into the service mode entered, press the t switch and
1) Operation method then enter the correct data start-
(1) Turn on the start switch of the vehicle ing from the highest digit.
to power ON the machine monitor. a You can return to the service
(2) While service meter screen or alert meter screen or alert screen by
screen is being displayed on the char- pressing the t switch when the
acter display of the machine monitor, cursor is located at the highest
press machine monitor mode selector digit.
switch 1 (t) and machine monitor a If any switch operation is not
mode selector switch 2 (<) at the done for 60 seconds or more dur-
same time for more than five seconds ing input of an ID. The screen
continuously, to enter into service ID will be returned to the service
input screen. The service ID input meter screen or alert screen.
screen is then displayed.
To enter into the service mode, input
Machine monitor mode selector switches 1, 2 "6491" as ID.
Supplementary explanation:
You can return to the service meter
screen or alert screen by turning OFF
the starting switch on the service
mode and then turn ON the starting
switch.
Service ID input screen
14 HD465-7R, HD605-7R
2. Service Mode Menu
(*1) If equipped the "Payload meter (having VHMS)".

(*2) If equipped the VHMS.
a On the service menu mode, the screen can be
changed by pressing switches </>. Use these
switches to select the desired operation menu
screen.
a While the following display screen (selection
screen) is being displayed, the screen can be
changed to the menu screen/operation screen
of each function by pressing switch U.
a While the following display screen (selection
screen) is being displayed, the screen can be
changed to the service meter screen of each
function by pressing switch t.
HD465-7R, HD605-7R 15
Operation menu screen (character display)

1) Electrical equipment system failure history screen 3) Real-time monitor screen
** indicates the number of currently memorized Outline

failure histories. Use this function to check the inputting and output-
(Up to max. 20 failure histories can be memo- ting signals being recognized by respective control-
rized.) lers on the network.
Outline
Use this function to check the electric system fail-
ure history of respective controllers being memo-
rized by the machine monitor. Regarding the error
code being used in the electric equipment system
failure history, refer to the Chapter "Troubleshoot-
ing". When the fault is repaired and after checking
and confirming that normal operation has been
restored, delete the fault history.
2) Vehicle system failure history screen 4) Engine reduced cylinder function screen
** indicates the number of currently memorized Outline

failure histories. Use this function to cut off the supply of fuel
(Up to max. 20 failure histories can be memo- sprayed from the fuel injector to each of the cylin-
rized.) ders in order to determine the cylinder where there
is defective combustion.
Outline Regarding the inspection method using this func-
Use this function to check the machine system fail- tion, refer to the Section "Reduced cylinder mode
ure history of respective controllers being memo- operation of engine" in the chapter "Inspection and
rized by the machine monitor. Regarding the error Adjustment"
code being used in the machine system failure his-
tory, refer to the Chapter "Troubleshooting".
16 HD465-7R, HD605-7R
5) No injection cranking function screen 7) Maintenance monitor function screen
Outline Outline
Use this function to lubricate an engine without This function is being explained in the section "Fil-
starting the engine to drive a vehicle after a long- ter and oil changing time indication on the character
term storage. display" in the Chapter "Handling" in the Operation
Regarding the engine start method using this func- and Maintenance Manual. Use this function to
tion, refer to the Section "No injection cranking change filter oil replacement interval and stop func-
operation of engine" in the chapter "Inspection and tion.
Adjustment"
6) Adjusting function screen 8) Operation information display function screen
Outline Outline
Use this function to correct installation errors of Use this function to display fuel consumption
sensors, solenoid valves, and compensate produc- amount per operation hour.
tion tolerances of parts and components. Use this
function to change control characteristic data in
response to user's request.
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Inspection and Adjustment"
HD465-7R, HD605-7R 17
9) Engine mode fixing function screen 11) Payload meter screen
Outline Outline
The engine mode controlled automatically accord- For details of this function, see "Related to VHMS
ing to the load on the machine, etc. is fixed forcibly. controller" of "Payload meter (having VHMS)".
This function is used to check the performance in
each engine mode.
10) Manual snapshot screen 12) Option selection function screen
Outline Outline
Use this function to order the snapshot data taking Use this function to indicate the installation status of
in, this function is used only having VHMS. When the optional equipment and to change the settings.
do the inspection used this function, see "Inspec- Use this function when optional equipment is
tion and Adjustment" of "Inspection using VHMS". installed or removed.
Regarding the setting change method using this
function, refer to the Section "Adjustment using
monitor" in the chapter "Inspection and Adjustment"
18 HD465-7R, HD605-7R
13) Model selection function screen
a Indicates the currently selected model.

Outline
Use this function to input and select machine
model.
14) Initialize function screen
Outline
This function operates on factory setting mode.
Since this function is for factory use only, do not
touch it.
HD465-7R, HD605-7R 19
Items related to the fault history of electric system

1) Selection of displaying and clearing the fault history of electric system
The fault history is displayed in the order of occurrence with the new fault first.
A current fault is displayed prior to the restored ones.
Pressing the > switch displays the next older fault.
Pressing the < switch displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the t switch changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the U switch changes the screen to the [Clear individually the fault history of electric sys-
tem] or [Clear the fault history of electric system] screen.
2) Selection of displaying the fault history of electric system (first layer)

Pressing the > switch changes the screen to the [Select the initializing function] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of vehicle sys-
tem] screen.
Pressing the t switch changes the screen to the ordinary or alert screen.
Pressing the U switch changes the screen to the [Display abnormalities in electric system] screen.
20 HD465-7R, HD605-7R
3) Selection of displaying the fault history of electric system and clearing the entire fault history of
electric system (second layer)
Pressing the > switch displays the next newer fault.
Pressing the < switch displays the next older fault.
Pressing the t switch changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the U switch changes the screen to the [Clear individually the fault history of electric sys-
tem] or [Clear the fault history of electric system] screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-
out clearing (but change the screen to that for individual clearing).
4) Clearing individually the fault history of electric system, and clearing the entire fault history of elec-
tric system (the third layer)
Select YES or NO with the < or > switch.
Cursor (_) blinks on the selected item. Pressing the t switch changes the display as follows, with
the history reset if YES was selected, or not if NO was selected:
i) If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
ii) If YES (clear ) was selected, the display returns to the [Display the fault history of electric sys-
tem] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
HD465-7R, HD605-7R 21
Items related to the fault history of machine system

1) Display of the fault history of vehicle system
Pressing the t switch changes the screen to the [Select displaying abnormalities in machine sys-
tem] screen on the first layer.
2) Selection of displaying the fault history of machine system (first layer)

Pressing the > switch changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of machine sys-
tem] screen.
Pressing the t switch changes the screen to the ordinary or alert screen.
Pressing the U switch changes the screen to the [Display abnormalities in electric system] screen.
22 HD465-7R, HD605-7R
3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the t switch changes the screen to the [Select displaying abnormalities in vehicle system]
screen.
HD465-7R, HD605-7R 23
Real-time monitoring function

The real-time monitor shows real-time the information which the controller mounted on the vehicle has.
This function is used for checking and adjustment, diagnosis of faults of the vehicle and other purposes.
The real-time monitor shows the items and their data, classified by the controllers which have information.
It shows them in two ways: the ordinary display, and the 2-item display where two data items are shown
simultaneously.
Operation
1. Press the t switch and < switch for more than five seconds to go to the [ID Entry] screen.
2. Enter ID with the < and > switch, and press the U switch to go to the screen for service persons.
3. Press the < and > switch to display the [Select the real-time monitor] screen, then press the U switch to
fix the screen.
24 HD465-7R, HD605-7R
4. Press the switch U, and the [Monitor information display/selection] screen appears. Press the switch <
and the switch > to display the [Transmission controller information display/selection] screen, [Engine
controller information display/selection] screen, [Retarder controller information display/selection]
screen, [ABS controller information display/selection] screen (if equipped) and [2 item display function
selection] screen in order.
5. Pressing the U switch, while each selection screen is shown, displays the [One-item display] screen or
the [Select information on 2-item display] screen.
***: Shows items.

%%%%%: Shows data and unit (SI system)
$$$$: Shows ID.
In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.
HD465-7R, HD605-7R 25
How to Enter an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the U switch.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last num-
ber is filled in the lowest digit.
If the lowest digit was entered, press the U switch, and the screen changes to that for displaying/selecting
the second item. Alternately, pressing the t switch returns the screen to that for displaying/selecting two
items.
In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.
6. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying
the information each controller has.
26 HD465-7R, HD605-7R
List of real-time monitoring display contents

The conditions of the input and output signals of the controller can be checked with the real-time monitoring
function of the monitor.
The following table shows the items related to the machine monitor and displayed with the real-time monitor-
ing function in the normal state.
No. Item ID No. Display of item Displayed data
1 Software No. 20020 VERSION Software No. is displayed.
2 Application ver. No. 20021 VERSION (APP) Application ver. No. is displayed.
3 Data ver. No. 20222 VERSION (DATA) Data ver. No. is displayed.
4 Rheostat 30300 RHEOSTAT Rheostat voltage is displayed.
5 Rotary switch 1 – 3 30800 SW1, SW2, SW3 –
6 DIP switch 5-1, 2 30900 SW5-1, SW5-2 SW5-1: Selection of SI or non-SI specifi-
cation
SW5-2: Unused
7 DIP switch 5-3, 4 30901 SW5-3, SW5-4 –
8 DIP switch 6-1, 2 30202 SW6-1, SW6-2 –
9 DIP switch 6-3, 4 30903 SW6-3, SW6-4 –
10 D-IN--0------7 40900 D-IN--0------7 Input signal is displayed.
11 D-IN--8------15 40901 D-IN--8------15 Input signal is displayed.
28 HD465-7R, HD605-7R
Contents of display in normal state Remarks
As per software No.
As per application version No.
As per data version No.
0 – 30 V
– Unused
SW5-1:
For 7831-46-7000*, normally OFF
For 7831-46-8000*, normally ON
SW5-2: Unused
– Unused
– Unused
– Unused
1 0000000 (Headlight = ON) D-IN-0: High beam

0 1 000000 (Switch = ON) D-IN-1: Machine monitor check switch
00 1 00000 (AISS switch = ON) D-IN-2: AISS switch
00000 1 00 (Switch = ON) D-IN-5: ABS system switch (if equipped)
If not equipped: 0
000000 1 0 (Switch = ON) D-IN-6: Passing switch
0000000 1 (Switch = Economy) D-IN-7: Engine mode switch
1 0000000 (Normally 1) D-IN-8: Connector check

0 0 000000 (Monitor mode switch (t) = ON) D-IN-9: Machine monitor mode switch (t)
00 1 00000 (Monitor mode switch (>) = ON) D-IN-10: Machine monitor mode switch (>)
000 1 0000 (Monitor mode switch (<) = ON) D-IN-11: Machine monitor mode switch (<)
0000 1 000 (Winker (Right) = ON) D-IN-12: Winker (Right)
00000 1 00 (Winker (Left) = ON) D-IN-13: Winker (Left)
000000 1 0 (Monitor mode switch (U) = ON) D-IN-14: Machine monitor mode switch (U)
0000000 0 (Unused) D-IN-15: Unused
HD465-7R, HD605-7R 29
12 D-IN-16-----23 40902 D-IN-16-----23 State of input signal is displayed.
15 D-OUT-0--3 40925 D-OUT-0--3 State of output signal is displayed.
30 HD465-7R, HD605-7R
0 0000000 (Switch = ON) D-IN-16: ARSC system switch (Upper) (If equipped)
If not equipped: 0
0 1 000000 (Switch = ON) D-IN-17: ARSC system switch (Lower) (If equipped)
If not equipped: 0
00 1 00000 (Switch = ON) D-IN-18: ABS system switch (Upper) (If equipped)
If not equipped: 0
000 1 0000 (Switch = ON) D-IN-19: ABS system switch (Lower) (If equipped)
If not equipped: 0
0000 1 000 (Switch = ON) D-IN-20: ASR system switch (Upper) (If equipped)
If not equipped: 0
00000 0 00 (Unused) D-IN-21: ASR system switch (Lower) (If equipped)
If not equipped: 0
000000 1 0 (Switch = ON) D-IN-22: Front brake cut-off switch
If not equipped: 0
1 0000000 (Headlight = ON) D-IN-24: Night lighting recognition

0 1 000000 (Seat belt = Installed) D-IN-25: Seat belt
00 1 00000 (Unused) D-IN-26: Unused

00 0 00000 (Normally 0) D-IN-34: Connector check
0000000 0 (Reservation for service, OP7 = OPEN) D-IN-39: Reservation for service
1 000 (Headlight Hi/Lo selector switch = ON) D-OUT-0: Headlight Hi/Lo selector switch
0 1 00 (Buzzer = ON) D-OUT-1: Buzzer
00 0 0 (Unused) D-OUT-2: Unused
000 0 (Unused) D-OUT-3: Unused
HD465-7R, HD605-7R 31
VHMS real monitor display table (if equipped)
1 Air temperature 37501 AIR TEMP Display air temperature
2 Air temperature 37504 AIR TEMP Display air temperature
3 Blow-by pressure 42801 BLOWBY PRESS Display blow-by pressure
4 Blow-by pressure 42802 BLOWBY PRESS Display blow-by pressure
5 Exhaust temperature 42610 EXHAUST TMP F Display exhaust temperature (FRONT)

(FRONT)
6 Exhaust temperature 42612 EXHAUST TMP F Display exhaust temperature (FRONT)

(FRONT)
7 Exhaust temperature (REAR) 42611 EXHAUST TMP R Display exhaust temperature (REAR)
8 Exhaust temperature (REAR) 42613 EXHAUST TMP R Display exhaust temperature (REAR)
9 Inclinometer (pitch angle) 32901 INCLINOMETER Display inclination angle
10 Inclinometer (pitch angle) 32902 INCLINOMETER Display inclination angle
11 Payload 42200 PAYLOAD Display payload
12 Rated payload 42201 RATE WEIGHT Display rated weight
13 Shift lever N signal 42500 SHIFT LEVER N Display shift lever N position
14 Stop run flag 45000 STOP RUN FLAG Display discrination the STOP or RUN
15 Suspension pressure (F.L.) 32805 SUS PRESS (FL) Display suspension pressure (F.L.)
16 Suspension pressure (F.L.) 32811 SUS PRESS (FL) Display suspension pressure (F.L.)
17 Suspension pressure (F.R.) 32804 SUS PRESS (FR) Display suspension pressure (F.R.)
18 Suspension pressure (F.R.) 32810 SUS PRESS (FR) Display suspension pressure (F.R.)
32 HD465-7R, HD605-7R
–30 to +100 [°C],

It depends on air temperature.
0.0 to 20.0 [kPa],

Refer Pm clinic inspection table.
0.0 to 20.0 [kPa],

0.5 [V] at 0 [kPa]

3.5 [V] at 15 [kPa]
Check after engine warm-up.

200 – 950 [°C]

0 to 5 [V]
2.2 [V] at 300 [°C]
3.9 [V] at 700 [°C]

200 – 950 [°C]

0 to 5 [V]
2.2 [V] at 300 [°C]
3.9 [V] at 700 [°C]
Flat ground: 0.0 [° ] (When Front up: plus, Measure- When PLM (having VHMS) is setted up.
ment range: +/–15°)
Flat ground: 2.6 [V] When PLM (having VHMS) is setted up.
4.15 [V] at +15°
1.06 [V] at –15°
Payload [t] (Always, Metric ton) When PLM (having VHMS) is setted up.
Rated payload [t] (Always, Metric ton) When PLM (having VHMS) is setted up.
When shift lever is N position: ON When PLM (having VHMS) is setted up.
When stoped: ON When PLM (having VHMS) is setted up.
0.00 – 20.0 [MPa] When PLM (having VHMS) is setted up.
1.0 [V] at 0 [Mpa] When PLM (having VHMS) is setted up.

2.0 [V] at 4.9 [Mpa]

2.0 [V] at 4.9 [Mpa]
HD465-7R, HD605-7R 33
19 Suspension pressure (R.L.) 32807 SUS PRESS (RL) Display suspension pressure (R.L.)
20 Suspension pressure (R.L.) 32813 SUS PRESS (RL) Display suspension pressure (R.L.)
21 Suspension pressure (R.R) 32806 SUS PRESS (RR) Display suspension pressure (R.R.)
22 Suspension pressure (R.R) 32812 SUS PRESS (RR) Display suspension pressure (R.R.)
23 Machin status 42400 TRUCK STATUS Display machine status
24 Input signal D_IN_0–7 40944 D-IN--0------7 Display input signal condition
25 Input signal D_IN_8–15 40945 D-IN--8-----15 Display input signal condition
26 Out put signal D_OUT_0–7 40946 D-OUT-0--3 Display input signal condition
27 SEL signal 0–3 40947 D-SEL--0--3 Display SEL signal condition
34 HD465-7R, HD605-7R

2.0 [V] at 4.9 [Mpa]

2.0 [V] at 4.9 [Mpa]
Empty Stooped: 1 When PLM (having VHMS) is setted up.

Empty Traveling: 2
During loading: 3
Loaded Traveling: 4
Losded Stopped: 5
During Unloading: 6

0 1 000000 (OBCOM connection = ON) D-IN-1: OBCOM connection
0000 1 000 (PLM2 connection = ON) D-IN-4: PLM2 conection
000000 1 0 (Cab under download SW = ON) D-IN-6: Cab under download SW
0000000 1 (Body float condition = ON) D-IN-7: Body float
1 0000000 (Protocol cange connector: automatic D-IN-0: Protocol cange connector

transmit = ON)
0 1 000000 (Protocol cange connector: MMS com- D-IN-1: Protocol cange connector
munication = ON)
0 000 (External display lamp: Green= light ON) D-OUT-0: External display lamp Green
0 0 00 (External display lamp: Yellow = light ON) D-OUT-1: External display lamp Yellow
00 0 0 (External display lamp: Red = light ON) D-OUT-2: External display lamp Red
000 1 (VHMS is in action) D-OUT-3: VHMS is in action
0 000 (Always 0) SEL-0: Always 0

0 1 00 (Always 1) SEL-1: Always 1
00 1 0 (Always 1) SEL-2: Always 1
000 0 (Always 0) SEL-3: Always 0
HD465-7R, HD605-7R 35
Engine cylinders cut-out function

Regarding the inspection method using this func-
tion, refer to the Section "Reduced cylinder mode
operation of engine" in the chapter "Inspection and
Adjustment"
This section will describe the operation method
only.
1. Press the t switch and < switch for more than

five seconds to go to the [ID Entry] screen.
2. Enter ID with the < and > switch, and press the
U switch to go to the screen for service per-
sons.
3. Press the < and > switch to display the [Select

the cylinder cut-out mode] screen, then press
the U switch to fix the screen.
36 HD465-7R, HD605-7R
4. How to operate the cylinder cut-out function

Each time the > switch is pressed (to select the cylinder to be cut-out with a command), the cursor
moves one step to the right.
Each time the < switch is pressed (to select the cylinder to be cut-out with a command), the cursor
moves one step to the left.
Pressing the U switch issues the command to cut-out the cylinder selected. Each time it is pressed, the
command toggles between cut-out and cancel.
Pressing the t switch returns the screen to that of [Select the cylinder cut-out mode], and any cut-out
command which has been issued from monitor is cancelled.
Example of operation: The command is issued to stop the third cylinder.
HD465-7R, HD605-7R 37
No injection cranking function screen

Regarding the engine start method using this function, refer to the Section "No injection cranking operation
of engine" in the chapter "Inspection and Adjustment"
This section will describe the operation method only.
38 HD465-7R, HD605-7R
Adjusting function
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Inspection and Adjustment"
This section will describe the operation method
only.
01: TM TRIGGER Transmission Initial learning

reset
a Refer to "Rest of Initial learning for Transmis-
sion and Learning Operation" in the chapter
"Adjustment"
02: ECMV TUNING ECMV compensation

a Refer to "Transmission ECMV Current Adjust-
ment" in the chapter "Adjustment".
HD465-7R, HD605-7R 39
Maintenance monitor function

1. Maintenance monitor selection display (first layer)
Regarding the screen, which the current
screen turns to when the <, >, or t switch is
pressed, refer to "Second Layer Transition Dia-
gram" in the Section "Service Person Func-
tion".
When the U switch is pressed, the current

screen turns to the [Maintenance item No. 1]
screen.
40 HD465-7R, HD605-7R
2. Maintenance item selection

1) Each time the > switch is pressed, the 2) Each time the < switch is pressed, the item
item No. of the displayed screen changes No. of the displayed screen changes from
from No. 1 in the ascending order. the largest number in the descending order.
a When the item No. of the displayed screen a When the item No. of the displayed screen
is the largest, pressing the > switch is No. 1, pressing the < switch changes
changes the screen to the "Default value the screen to the "All timer stop/all item
is set" screen. valid" screen.
a. Maintenance interval time change (4) The cursor moves to the second highest digit.
Repeat the procedures mentioned in (2) and (3)
until the last number is filled in the lowest digit.
(5) After the lowest digit is entered, press the U
switch.
a If the entered value represents the interval
time which can be set, the screen changes to
the confirmation screen.
a If the entered value represents the interval
time which cannot be set, the time doe not
change.
(6) The cursor is returned to the highest digit.
a The interval time can be set up to 50 h.
(7) If a wrong number is entered, unless the cursor
is positioned at the highest digit, press the t
switch to bring the cursor to the highest digit,
and do the procedures from the beginning again.
a At this time, the entered values remain
unchanged.
(8) When the cursor is positioned at the highest
digit, pressing the t switch changes the
screen to the higher layer.
q Press the <> switch to select YES/NO.
q The cursor (_) blinks on the selected item
When YES is selected, pressing the t switch
accepts the change. When NO is selected,
pressing the t switch cancels the change, and
How to enter interval time goes to the "maintenance item selection"
(1) Enter a number from 0 to 9 in the cursor posi- screen.
tion. a The cursor is positioned at NO by default to
(2) The cursor is positioned at the highest digit prevent from mistakenly carrying out the reset
first. Each time the > or < switch is pressed, operation.
the number is changed in the INC/DEC order q When the interval time is changed, the remain-
by 1 within a range 0 to 9. ing time on the timer is as follows.
(3) If the desired number is entered, press the U [Set interval time – time elapsed from the previous
switch to apply it. operation]
HD465-7R, HD605-7R 41
b. Item specific timer stop/item specific valid 3. Default individual setting

selection
q Press the <> switch to select YES/NO.

q When "item specific timer" is currently operat- q The cursor (_) blinks on the selected item.
ing, "ON o OFF" is displayed on the lower When YES is selected, pressing the t switch
panel. accepts the change. When NO is selected,
q When "item specific timer" is currently stop- pressing the t switch cancels the change, and
ping, "OFF o ON" is displayed on the lower goes to the "maintenance item selection"
panel. screen.
a The timer function should be valid by default a The cursor is positioned at NO by default to
with [ON] displayed. prevent from mistakenly carrying out the reset
q Setting "Item specific timer" to stop state, operation.
[OFF] is displayed on the higher panel. q For each maintenance item, the timer should
q Setting "Item specific timer" to operation state, be set to stop/stop release.
[ON] is displayed on the higher panel. q Set the timer to stop/ release from stop for
q Press the <> switch to select YES/NO. each of the maintenance items.
q The cursor (_) blinks on the selected item. q When the timer is made enables after it was
When YES is selected, pressing the t switch stopped, the interval time set to the timer
accepts the change. When NO is selected, before the timer was disabled is restored.
pressing the t switch cancels the change, and a The remaining time on the timer is reset.
goes to the "maintenance item selection" a The number of reset times is not incremented
screen. but remains the same.
a The cursor is positioned at NO by default to pre-
vent from mistakenly carrying out the reset op-
eration.
q Set the timer to stop/ release from stop for
each of the maintenance items.
q When the timer is made enabled after it was
stopped, the interval time set to the timer
before the timer was disabled is restored.
q The remaining time on the timer is reset.
a The number of reset times is not incremented
but remains the same.
42 HD465-7R, HD605-7R
4. "All item timer stop/all item valid selection"
*1. Press the U switch to change the screen to the "All item timer stop" screen.
*2. In the case that "All item timer stop" is selected
*3. When all item stop is carried out:
The timer functions for all items are disabled, and the screen returns to the "Maintenance monitor
selection" screen.
When the specific item is carried out, the setting is made to disable the function.
When cancel is carried out:
The operation is cancelled and the screen returns to the "maintenance selection" screen.
*4. When "All item valid" is selected
*5. Press the <> switch to select YES/NO.
The cursor (_) blinks on the selected item
a The cursor is positioned at NO (not change) by default to prevent from mistakenly carrying out the
reset operation.
*6. When all item valid is carried out:
Regardless of whether specific item is valid or invalid, the interval time set to the timer before the timer
was disabled is effective for all items.
The remaining time on the timer is reset.
Meanwhile, the number of reset times is not incremented but remains the same.
The screen returns to the "maintenance monitor selection" screen.
Setting is made valid for each item.
When cancel is carried out:
The operation is cancelled and the screen returns to the "maintenance selection" screen.
HD465-7R, HD605-7R 43
5. Maintenance monitor item
English message
No. Item Interval [h] ID number
[11 one-byte characters]
1 Pre fuel filter 500 P FUEL FILT 41
2 Engine oil 500 ENG OIL 01
3 Engine oil filter 500 ENG FILT 02
4 Transmission oil filter 500 TM FILT 13
5 Fuel filter 1,000 FUEL FILT 03
6 Corrosion resistor 1,000 CORR RES 06
Torque converter, transmission and
7 1,000 TC/TM/BK OIL 24
rear brake cooling oil
8 Brake oil filter 1,000 BK OIL FILT 14
9 Brake cooling oil filter 1,000 BK C FILT 16
10 Hydraulic oil filter 2,000 HYD FILT 04
11 Differential case oil 2,000 DIFF OIL 11
12 Final drive oil 2,000 FNL OIL 08
13 Steering hoist oil 4,000 HYD OIL 10
44 HD465-7R, HD605-7R
Operation information display function

Outline
q The fuel consumption value is calculated based on the target injection quantity information supplied
from the engine controller.
q The fuel consumption value can be used merely as a reference value because the actual fuel consump-
tion is not measured.
*1 Lower column
Upper column q Displays travel distance (km or mile) since the
q Displays fuel consumption (L/km or L/mile) for previous reset
every 1 km (or mile) since the previous reset q Counting will stop when the upper limit
q Calculation is made based on the above fuel 9999999.9 is reached.
consumption and the travel distance *3
q Counting will stop when the upper limit Upper column
99999.9 is reached. q Displays accumulated fuel consumption (L)
Lower column since the previous reset
q Displays average fuel consumption (L/h) since q Counting will stop when the upper limit
the previous reset 9999999.9 is reached.
q Counting will stop when the upper limit 9999.9 Lower column
is reached. q Displays elapsed time (h) since the previous
*2 reset
Upper column q Counting will stop when the upper limit
q Displays accumulated fuel consumption (L) 9999999.9 is reached.
since the previous reset
q Counting will stop when the upper limit
9999999.9 is reached.
HD465-7R, HD605-7R 45
*4 *6
(if equipped the VHMS) Setting of gain compensation value
q Display loaded quantity {ton} from the last 1) In order to change the screen, display the cur-
reset on the upper line. rent setting value and place the cursor on the
q Stop at the upper limit of 999999999.9. symbol (+/–).
q Whether short ton or metric ton is used 2) While the cursor is being positioned at the
depends on option settings. symbol, repeat '+', '<–>', '–', each time the >, /,
q Display the number of loadings from the last or < switch is pressed.
reset on the upper line. 3) Press the U switch to confirm the symbol. o
q Stop at the upper limit of 999999999.9. The cursor moves to the highest digit.
a The above data should be obtained from the 4) The cursor is positioned at the highest digit
value calculated by VHMS when PLM built into first. Each time the >, /, or < switch is pressed,
VHMS is enabled. the number is changed in the INC/DEC order
a VHMS sends load capacity to a monitor panel by 1 within a range 0 to 9 (the highest digit is 0
at the time of determination of 1 cycle. to 2).
a When load capacity at the time of determina- 5) If the desired number is entered, press the U
tion of 1 cycle is received, the monitor panel switch to apply it.
adds the loaded quantity to the last value and 6) The cursor moves to the lower digit. Repeat
add 1 to the number of loadings. the procedure mentioned in 4).
*1 – *4 7) The cursor moves to the lowest digit. Press
q Calculation is made only when engine is oper- the U switch. (When the number is confirmed,
ating and optional equipment is provided. the screen returns to that of the previous
*5 layer.)
q Press the U switch to delete data in the 8) While the number is being entered, pressing
screen (*1), (*2), (*3) and return to the screen the t switch makes the number remain
of the previous layer. unchanged and the cursor returns to the posi-
q Press the t switch to return to the screen of tion of the symbol. Pressing the t switch
the previous layer without resetting the current again change the screen to the previous
screen. screen.
a Reset the data when "initializing the monitor 9) When the number is not within the range from
panel" and when "turning the optional functions – 50.0 to + 50.0 while the lowest digit is con-
OFF", in addition to the above resetting opera- firmed, the number remains unchanged and
tion. the cursor returns to the position of the symbol,
as is the case for pressing the t switch.
Obtaining fuel consumption level [L]
q The monitor panel calculates the accumulated Procedures with the monitor panel:
fuel consumption (L) based on the instanta- q Default value: 0.0%
neous fuel consumption [L/h] supplied from the q Specify the setting value to compensate the
engine controller. accumulated fuel consumption (L) in the range
q The accumulated fuel consumption (L) is com- of [– 50.0 to + 50.0]
pensated using the fuel adjusting function
[FUEL ADJUST] on the service mode.
q The instantaneous fuel consumption [L/h] sup-
plied from the engine controller is compen-
sated in accordance with the table shown
below.
[Compensated value in accordance with the table]

= [Instantaneous fuel consumption supplied from
engine controller] x [compensation value (a)]
Model Compensation value (a)
HD325-7, HD405-7 1
HD465-7E0, HD605-7E0 1
HD465-7R, HD605-7R 1
HD785-7 1
46 HD465-7R, HD605-7R
RDT snapshot (having VHMS)

For information about this function, see the section "Implementation of PM Clinic Using Manual Snapshot".
(*1)
Start the snapshot and exit it during recording.
After 7 minutes 30 seconds have elapsed, a move
to "READY" takes place when U is pressed on the
"SNAPSHOT" screen.
When 7 minutes 30 seconds have not elapsed, a
move to the "EXECUTING" screen takes place.
HD465-7R, HD605-7R 47
Engine mode fixing function

Outline
q This function is used to check the engine per-
formance. (High idle speed and torque con-
verter stall speed)
q There are 4 engine modes (A, B, C, and D). If
a mode is selected by the following operation,
it is transmitted to the transmission controller.
Then, transmission controller orders the
engine controller to operate in that mode.
q While this screen is displayed, run the engine
at high idle or stall the torque converter and
check the engine speed in each case.
q If this screen changes to another, the engine
mode fixing function is reset.
q For the standard values of the engine in A, B,
C, and D, see the standard value table.
a Before using this function, check the following.
q The parking brake is turned ON.
q No errors are made.
48 HD465-7R, HD605-7R
Payload meter (if equipped of VHMS)

a Setting of this function, see "Structure, function
and maintenance" of "Payload meter (having
VHMS)".
Option selecting function

a Regarding the setting method using this func-
tion, refer to the Section "Adjustment using
monitor" in the chapter "Inspection and Adjust-
ment".
Model setting function

a Regarding the setting method using this func-
tion, refer to the Section "Adjustment using
monitor" in the chapter "Inspection and Adjust-
ment".
HD465-7R, HD605-7R 49
Table of signals for each monitor connector
Machine monitor
No. Specification
CN PIN I/0 A/D
1 CN1 1 – – –
2 CN1 2 – – –
3 CN1 3 – – –
4 CN1 4 – – NSW power supply (+24 V)
5 CN1 5 – – NSW power supply (+24 V)
6 CN1 6 – – SW power supply (+24 V)
7 CN1 7 – – SW power supply (+24 V)
8 CN1 8 – – –
9 CN1 9 – – GND
10 CN1 10 – – GND
11 CN1 11 0 D D_OUT_3, (Sync 200 mA)
12 CN1 12 0 D D_OUT_2, (Sync 200 mA)
13 CN1 13 0 D D_OUT_1, (Sync 200 mA)
14 CN1 14 0 D D_OUT_0, (Sync 200 mA)
15 CN1 15 – – Sensor power output (+24 V, 100 mA)
16 CN1 16 – – Sensor power output (+5 V, 100 mA)
17 CN1 17 – – GND
18 CN1 18 – – GND
19 CN1 19 – – GND
20 CN1 20 – – GND
21 CN2A 1 I D D_IN_0, (+24 V, 5 mA, PULL DOWN)
27 *1 CN2A 7 I D D_IN_12, (NSW+24 V, 5 mA, PULL DOWN)
28 *1 CN2A 8 I D D_IN_14, (NSW+24 V, 5 mA, PULL DOWN)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
50 HD465-7R, HD605-7R
Signal and model

Model name
Remarks
Signal name HD325-7 HD465-7E0 HD465-7R
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – – (–) : NON CONNECT
– – – – – OPEN (RESERVED)
– – – – – OPEN (RESERVED)
BAT DIRECT +24 V Q Q Q Q Directly from battery +24 V
BAT DIRECT +24 V Q Q Q Q Directly from battery +24 V
POWER SUPPLY +24 V Q Q Q Q Key switch +24 V (ACC)
POWER SUPPLY +24 V Q Q Q Q Key switch +24 V (ACC)
– – – – – (–) : NON CONNECT
GND (for power supply) Q Q Q Q +24 V POWER CONNECT
GND (for power supply) Q Q Q Q +24 V POWER CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
BUZZER OUTPUT Q Q Q Q Warning buzzer (Max. 200 mA sync)
HEAD LIGHT H/L SWITCHING Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
HI BEAM Q Q Q Q
AISS SW Q Q Q Q
EXHAUST SW2 – – – Q Exhaust brake switch lower side
PASSING SW Q Q Q Q
Used to detect improper connector,
CONNECTER CHECK Q Q Q Q connection
MODE SW2-1 > Q Q Q Q Mode SW2 upper side
RIGHT TURN Q Q Q Q
MODE SW1-1 U Q Q Q Q Mode SW1 upper side
HD465-7R, HD605-7R 51
Machine monitor
No. Specification
CN PIN I/0 A/D
29 CN2A 9 – – GND
30 CN2A 10 I D D_IN_1 (+24 V, 5 mA, PULL DOWN)
31 CN2A 11 I D D_IN_3 (+24 V, 5 MA, PULL DOWN)
36 *1 CN2A 16 I D D_IN_13 (NSW+24 V, 5 MA, PULL DOWN)
37 *1 CN2A 17 I D D_IN_15 (NSW+24 V, 5 MA, PULL DOWN)
38 CN2A 18 I A D_IN_0 (0 – 30 V)
39 CN2B 1 I D D_IN_16 (+24 V, 5 MA, PULL UP)
43 CN2B 5 I D D_IN_24 (+24 V, 5 MA, PULL DOWN)
44 CN2B 6 – – GND
49 CN2B 11 I D D_IN_25 (+24 V, 5 MA, PULL DOWN)
50 CN2B 12 I A A_IN_1 (0 – 30 V)
54 *2 CN3A 4 I D D_IN_32 (GND, 5 MA, PULL UP)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
*2: Setting is made to PULL UP.
52 HD465-7R, HD605-7R
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
SENSOR GND Q Q Q Q
CHECK SW Q Q Q Q
EXHAUST BRAKE SW1 – – – Q Exhaust brake switch upper side
ABS CHECK SW Q Q Q Q
ENGINE MODE SW Q Q Q Q
MODE SW1-2 t Q Q Q Q Mode SW1 lower side
MODE SW1-2 < Q Q Q Q Mode SW1 lower side
LEFT TURN Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
ARSC SYSTEM SW1 Q Q Q Q ARSC system switch (upper)
ABS SYSTEM SW1 Q Q Q Q ABS system switch (upper)
ASR SYSTEM SW1 Q Q Q Q ASR system switch (upper)
FRONT BRAKE CUT OFF Q Q Q – (–) : NON CONNECT

Head Light SW recognition for Night
NIGHT LIGHTING SW +24 V Q Q Q Q Lighting function
SENSOR GND Q Q Q Q
ARSC SYSTEM SW2 Q Q Q Q ARSC system switch (lower)
ABS SYSTEM SW2 Q Q Q Q ABS system switch (lower)
ASR SYSTEM SW2 Q Q Q Q ASR system switch (lower)
– – – – – (–) : NON CONNECT
SEAT BELT Q Q Q Q
PANEL DIMMER SWITCH Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT

CONNECTOR CHECK 2 (–) : NON CONNECT, Used to detect
(OPEN) Q Q Q Q improper connector connection
– – – – – (–) : NON CONNECT
HD465-7R, HD605-7R 53
Machine monitor
No. Specification
CN PIN I/0 A/D
57 *2 CN3A 7 I D D_IN_38 (GND, 5 mA, PULL UP)
58 CN3A 8 I P P_IN_0 (0.5 Vp-p)
59 CN3A 9 – – GND
62 CN3A 12 I D –
67 CN3A 17 I P P_IN_0 (0.5 Vp-p)
68 CN3A 18 – – NC
69 CN3B 1 I A A_IN_2 (High resistance input)
71 CN3B 3 I A A_IN_6 (Low resistance input)
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 – – GND
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 – – GND
80 CN3B 12 – – NC
81 CN4 1 – – S_NET (+)
82 CN4 2 – – S_NET (+)
83 CN4 3 – – CAN (+)
84 CN4 4 – – S_NET (–)
*2: Setting is made to PULL UP.
54 HD465-7R, HD605-7R
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
OP7 Q Q Q Q For service mode
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
CAN (+) Q Q Q Q
– – – – – (–) : NON CONNECT
HD465-7R, HD605-7R 55
Machine monitor
No. Specification
CN PIN I/0 A/D
85 CN4 5 – – S_NET (–)
86 CN4 6 – – GND
87 CN4 7 – – GND
88 CN4 8 – – CAN (–)
89 CN4 9 – – NC
90 CN4 10 – – NC
91 CN4 11 – – NC
92 CN4 12 – – NC
93 CN5 1 – – NC
94 CN5 2 – – RA232C_1_RTS
95 CN5 3 – – RA232C_1_RD
96 CN5 4 – – RA232C_2_RD
97 CN5 5 – – RA232C_2_RTS
98 CN5 6 – – NC
99 CN5 7 – – NC
100 CN5 8 – – RA232C_1_CTS
101 CN5 9 – – RA232C_1_TX
102 CN5 10 – – RA232C_1_SG
103 CN5 11 – – RA232C_2_SG
104 CN5 12 – – RA232C_2_TX
105 CN5 13 – – RA232C_2_CTS
106 CN5 14 – – NC
107 CN6 1 – – –
108 CN6 2 – – –
109 CN6 3 – – –
110 CN6 1 – – NC
111 CN6 5 – – –
112 CN6 6 – – NC
113 CN6 7 – – –
114 CN6 8 – – GND
56 HD465-7R, HD605-7R
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– Q Q Q Q (–) : NON CONNECT
CAN SHIELD GND Q Q Q Q
CAN (–) Q Q Q Q
– Q Q Q Q
– Q Q Q Q
– Q Q Q Q
Q Q Q Q
Q Q Q Q (–) : NON CONNECT
CAN (+) Q Q Q Q (–) : NON CONNECT
– Q Q Q Q
HD465-7R, HD605-7R 57
a Switch input on monitor panel board
No. SW Position I/0 A/D Specification
1 SW1 0 I D
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
Rotary switch (16 pousitions)
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
17 SW2 0 I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
Rotary switch (16 positions)
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
58 HD465-7R, HD605-7R
Model name
Signal name HD325-7 HD465-7E0 HD465-7R Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD465-7R, HD605-7R 59
No. SW Position I/0 A/D Specification
33 SW3 0 I D
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
Rotary switch (16 positions)
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
49 SW5 1 I D Dip switch (2 positions)
50 SW5 2 I D
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D Rotary switch (16 positions)
54 SW6 2 I D
55 SW6 3 I D
56 SW6 4 I D
60 HD465-7R, HD605-7R
Model name
Signal name HD325-7 HD465-7E0 HD465-7R Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
ON: SI specification
– – – –
OFF: Non-SI specification
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD465-7R, HD605-7R 61

© 2006 KOMATSU
All Rights Reserved
62 HD465-7R, HD605-7R
SEN02300-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Automatic shift control system ........................................................................................................................ 2
Transmission controller ................................................................................................................................... 6
Automatic emergency steering system ......................................................................................................... 20
Automatic suspension system ...................................................................................................................... 22
Retarder control system................................................................................................................................ 25
HD465-7R, HD605-7R 1
Automatic shift control system 1

1. Electrical circuit diagram
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Outline RTCDB2(Machine monitor, retarder controller, and

q Upon receiving the shift position signal of the the other) (Updated for 100 msec)
gear shift lever, acceleration signal of the No. Item
accelerator pedal, speed signal of the trans-
1 Gear speed
mission, and signals of various switches and
2 Shift lever position
sensors, the transmission controller automati-
3 Lock-up operation condition
cally sets the transmission in the most suitable
gear speed. 4 Torque converter condition
q The transmission controller controls the torque 5 Emergency escape condition
converter lockup system and the brake to pre- 6 Operating state of overrun prevention brake
vent overrun, as well as the transmission. 7 Model setting abnormality condition
Each of the clutch packs of the transmission 8 Option setting abnormality condition
and the torque converter lockup clutch pack 9 Neutral safety alarm
has the electronically controlled modulation 10 Operation of overrun alarm
valves to control the clutches independently. 11 –
Those valves control the initial pressure, build- 12 –
up rate, and torque-off time of each clutch
13 Alternator R terminal
according to the condition of the machine to
14 key switch C terminal
reduce the gear shift shocks, prevent gear shift
15 Emergency steering operation
hunting, and improve the durability of the
clutch. 16 Tipping alarm command
q Upon receiving the signals of the switches and 17 Fuel level
sensors to drive the display, cautions, and pilot 18 Control state of grid heater
lamps of the machine monitor, the transmis- 19 Engine water temperature
sion controller sends them to the network. 20 Engine speed
21 Momentary fuel consumption
Data item transmitted from the transmission 22 Body seating
controller to the network 23 Float caution
24 Auto suspension mode
RTCDB1(Machine monitor, retarder controller, and
25 Retarder brake signal
the other) (Updated for 10 msec)
26 Parking brake signal
No. Item 27 –
1 Output shaft rotation number Tail lamp operation (secondary brake operation
28
2 – recognition)
3 Brake command(Rear wheel) 29 ARSC operation (ready lamp)
4 – 30 ASR command (oparation ON/OFF)
31 ABS operation condition
Retarder controller model setting abnormality
RTCDB1(Dedicated to engine controller) 32
condition
(Updated for 10 msec)
Retarder controller option setting abnormality
33
No. Item condition
1 Throttle correction value Accumulator oil temperature drop condition
34
2 Throttle lower limit (front,rear)
3 Throttle upper limit 35 ARSC overheat alarm
4 2nd method throttle 36 ABS controller model setting abnormality condition
5 HS line / brake point rotation number 37 ABS controller option setting abnormality condition
6 Torque curve select (engine mode) 38 ARSC setting travel speed
7 ABS reference type 39 –
8 Droop switch 40 Retarder oil temperature (rear)
9 ABS droop trim 41 Body positioner signal
RTCDB2(Dedicated to engine controller)

(Updated for 100 msec)
No. Item
1 Automatic warming-up cansel flag
4 HD465-7R, HD605-7R
Data item transmitted from the transmission RPC-k (irregularly updated)

controller to the network
No. Item
1 Model selection information
RTCDB1 (Updated for 10 msec)
Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator opening b. Maximum gear speed setting for the body-up
state
3 Seat unoccupied judgment
c. Exhaust brake equipped / not equipped
4 Reverse not-permitted command 2
d. Correction amount of tire size
5 – e. ELVIS function Installed/Not installed
6 Retarder switch (rear) condition f. Tipping alarm function Installed/Not installed
7 Foot brake (service brake) condition g. ABS function Installed/Not installed
h. Parking brake interlock provided / not pro-
vided
RTCDB2 (Updated for 100 msec) Adjustment mode information
No. Item (Adjustment mode information)
1 Service meter 3 a. Trigger correction amount leaning value reset
b. Auto IP mode command
2 Engine mode switch
c. Manual IP mode command
3 –
4 –
5 AISS inhibit switch
6 Reverse travel speed selector switch
7 Accelerator sensor abnormality condition
8 Engine water temperature
9 Control state of grid heater
10 Momentary fuel consumption
11 Parking brake operation
12 Retarder brake operation
13 Body seating
14 Hoist lever condition
Tail lamp output (secondary brake operation
15
recognition)
16 Float caution
17 ASR command (operation ON/OFF)
18 ARSC operation (ready lamp)
19 ARSC setting travel speed
20 ARSC overheat alarm
21 –
22 –
23 Retarder oil temperature (rear)
24 Auto suspension mode
Retarder controller option setting abnormality
25
condition
Retarder controller model setting abnormality
26
condition
27 Body position sensor
28 ABS operation condition
ABS controller option setting abnormality
29
condition
ABS controller model setting abnormality
30
condition
HD465-7R, HD605-7R 5
Transmission controller 1
Outline
q The transmission controller controls the trans- 7. It receives the model selection data (what
mission system. model it is mounted on) through the net-
It has the following features and functions. work.
1. It has a power mode and an economy 8. It has a self-diagnostic function which di-
mode, and the gearshifting pattern can be vides the input and output systems further
selected. into small parts.
2. The braking mode is the mode when the 9. The self-diagnostic function is displayed
brake is used. By raising the gearshifting on the monitor.
point and increasing the speed of the 10. When an abnormality is detected, it trans-
brake cooling pump it is possible to raise mits the details to the network.
the cooling effect of the retarder and make 11. It uses the machine monitor to display if the
effective use of the engine brake. failure is still existing.
3. It controls the brake through the retarder 12. It provides an escape function for use
controller for the torque converter lock-up when there is a failure in the electrical sys-
solenoid valve and overrun prevention. tem.
4. To reduce the shock when shifting gear, it
outputs the throttle correction command to
the engine controller when shifting gear
and adjusts the engine speed.
5. Speed sensors are installed at three plac-
es (transmission input shaft, intermediate
shaft, and output shaft). This makes it pos-
sible to detect slippage of the transmission
clutches and to protect the transmission
when there is any abnormality in the hy-
draulic system.
6. It connects to the network and shares var-
ious data with other controllers.
6 HD465-7R, HD605-7R
Input and output signal

ATC1
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Torque converter oil pressure Input 13 Accumulator oil pressure sensor (front) Input
2 – – 14 –
3 Transmission oil temperature Input 15 Alternator R terminal Input
4 – – 16 Sensor power supply Output
5 Emergency escape switch Input 17 Transmission filter clogging switch 1 Input
6 Shift lever position N Input 18 – –
7 Accumulator oil pressure sensor (rear) Input 19 Machine inclination angle Input
8 Fuel level sensor Input 20 Steering oil temperature Input
9 Torque converter oil temperature Input 21 GND (for sensor) –
10 – – 22 Sensor power supply (5V) Output
11 – – 23 – –
12 Emergency steering operation Input 24 Start Input
ATC2
1 – – 21 –
2 – – 22 Network Low Imput/output
3 – – 23 –
4 – – 24 –
5 Shift lever position 5 Input 25 Shift lever position D Input
6 Shift lever position L Input 26 Shift lever position 3 Input
7 T/M main variable valve operation Input 27 Coolant level Input
8 – – 28 – –
9 – – 29 GND (for input shaft rotation, output shaft Input
rotation)
10 – – 30 Transmission output shaft rotation Output
11 – – 31 –
12 – – 32 Network High Input/output
13 – – 33 – –
14 – – 34 – –
15 Shift lever position 6 Input 35 Shift lever position R Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Air cleaner clogging switch Input 37 – –
18 – – 38 – –
19 – – 39 GND (intermediate shaft rotation) Input
20 Transmission intermediate shaft rotation Input 40 Transmission input shaft rotation Input
ATC3
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24 V Input 22 Proportional solenoid power supply 24 V Input
ECMV Hig 1st, 4th, main oil quantity change ECMV Rev. 2nd, lock-up, T/M lubrication oil
3 valve (-) Output 23 quantity variable valve (-) Output
4 – – 24 KEY switch ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV Low (+) Output 26 ECMV Hig (+) Output
7 – – 27 – –
8 Torque converter oil pressure sensor power Output 28 – –
supply (24V)
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Fill switch Low Input 30 Fill switch Hig Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24 V Input 32 GND Input
13 ECMV output Low, 3rd (-) Output 33 GND Input
14 KEY switch ACC Input 34 – –
15 ECMV 3rd (+) Output 35 ECMV lock-up (+) Output
16 ECMV 4th (+) Output 36 ECMV 1st (+) Output
17 – – 37 T/M main pressure variable valve Output
18 – – 38 – –
19 Fill switch 3rd Input 39 – –
20 Fill switch 4th Input 40 Fill switch 1st Input
HD465-7R, HD605-7R 7
Gear shift lever position and automatic gearshifting range

q The relationship between each gear shift position and the automatic gearshifting range is as shown in
the table below.
Gearshifting characteristics Braking mode:

q Shifting the transmission up and down is car- The shift-down point and the shift-up point are both
ried out according to the shift map saved in the raised, the engine speed is maintained at a higher
controller memory. level, and the amount of cooling oil for the retarder
There are five types of shift map, depending on is ensured to provide greater effect when the engine
the condition of the input signals. is used as a brake.
The settings for each mode are as shown in
the table below. Coasting mode:
The shift-down point and the shift-up point become
Mode Set conditions close to each other to decrease the occurrences of
Braking mode Brake signal ON
unnecessarily shifting transmission.
When either of the following conditions is fulfilled Partial delay:

Coasting
1. Brake signal OFF
mode
2. Accelerator idle Unnecessary gear shift operations caused by the
change of the mode are reduced.
When following conditions are satisfied
1. Within certain time after brake signal is turned
Partial delay OFF Power mode:
2. Accelerator pedal is not in idle position or full The power mode uses the power of the machine to
position
the maximum to provide the maximum payload.
When the following conditions are fulfilled However, when the machine is unloaded or has only
1. Certain time after brake signal is turned OFF a light load (high acceleration), an acceleration sen-
Power mode
2. Accelerator pedal depressed
3. Power mode selector switch is at power sitive type variable shifting point is used. This de-
tects the acceleration of the machine and shifts the
When the following conditions are fulfilled
Economy 1. Certain time after brake signal is turned OFF
transmission up sooner to provide better accelera-
mode 2. Accelerator pedal depressed tion and to improve the fuel consumption, noise, and
3. Power mode selector switch is at economy transmission shock.
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. In this mode, the max-
imum engine output is limited.
8 HD465-7R, HD605-7R
Automatic gearshifting graph

q 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.
Note:
1. Power mode gear speed (F4, F3, or F2) is maintained.
q For the shift-up point, the optimum point Accordingly, if the operator drives the machine
between 2,100 and 1,750 rpm is selected down a slope with the foot brake applied and
according to the amount of the accelerator the engine speed is kept low by the gear speed
pedal is depressed, the acceleration of the maintaining function, the cooling oil becomes
machine, and the speed range. insufficient and the engine tends to overheat.
q For the shift-down point also, the optimum q If the travel speed lowers below 1 km/h or the
point between 1,200 and 1,400 rpm is selected foot brake is not applied or the lock-up is kept
according to the amount the accelerator pedal turned on for a long period, the lock-up is
is depressed and the speed range. turned off and a gear speed proper for the
travel speed is selected.
2. Economy mode
q For the shift-up point, the optimum point 4. Lock-up
between 2,100 and 1,750 rpm is selected q The point to turn ON the torque converter
according to the amount the accelerator pedal lockup is set properly in the range from 1,250
is depressed, the acceleration of the machine, to 1,500 rpm according to the torque converter
and the speed range. inlet speed (engine speed) and outlet speed
q For the shift-down point also, the optimum (transmission input shaft speed) and accelera-
point between 1,200 and 1,400 rpm is selected tor pedal position.
according to the amount of the accelerator q The lockup-off point is 1,100 rpm.
pedal is depressed and the speed range. q If the operator starts driving the machine down
a slope with the accelerator pedal released,
3. Braking mode
the torque converter is not locked up until the
q While the foot brake is operated, if the travel
operator presses the accelerator pedal or
speed lowers below about 20 km/h at the 4th
applies the brake.
gear speed, about 15 km/h at 3rd gear speed,
or 11 km/h at the 2nd gear speed, the current
HD465-7R, HD605-7R 9
Gear shift lever positions and method of shifting 4) Gear shift lever position N
1) Gear shift lever position D At the neutral position, none of the transmis-
When shifting up (in power mode) sion clutches are actuated.
I) When the gear shift lever is set at position D,
the transmission is set to F2 torque converter Time when gear cannot be shifted
range. q In the automatic shift range, to prevent mis-
II) When the accelerator pedal is depressed, the taken operation caused by excessive variation
engine speed rises and accelerates. When the in the speed when shifting gear, a time delay is
transmission input shaft speed reaches 1,250 used to prevent the gears from being shifted
– 1,500 rpm, the lock-up clutch is engaged, so within the set time.
the torque converter is directly engaged and q The gearshifting time delay is controlled pre-
the transmission is set to direct travel. cisely by each gearshifting pattern through the
III) As the engine speed rises further and reaches use of the all-range electronic modulation sys-
1,750 – 2,100 rpm, the transmission shifts up tem.
to F3.
While the transmission is shifting up, the The approximate values for the gearshifting
engine speed is also lowered (a command is pattern and gearshifting time delay are shown
output to the engine controller) in order to in the diagram below.
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 power mode)

I) When the load increases and the engine
speed drops to 1,200 – 1,550 rpm, the trans-
mission shifts down one speed.
(For example, when traveling in F7, the trans-
mission shifts down to F6.)
While the transmission is shifting up, 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 disengaged
and the transmission enters the torque con-
verter drive.
a In the above explanation, the set speed or

actuation may differ according to the travel
conditions. For details, see the automatic
gearshifting graph.
2) Gear shift 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 "gear
shift lever position D" above.
3) Gear shift lever positions R
There is the gear shift lever position for travel-
ing in reverse.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
10 HD465-7R, HD605-7R
Safety functions 4) Power train overrun prevention rear brake

1) Down-shift inhibitor function function
If gear shift lever is operated D o 6 - L, 6 o 5 - If the engine speed rises to more than 2,550
L, 5 o 4 - L, 4 o 3 - L, 3 o 2 - L, 2 o L rpm, the central warning lamp flashes and the
For example, when traveling in D (F7), even if alarm buzzer sounds.
the gear shift lever is operated to 5, the trans- If the engine speed rises to more than 2,500 to
mission does not shift directly F7 o F5. It 2,600 rpm, the rear brake is automatically
shifts down F7 o F6 o F5 in turn according to actuated.
the travel speed. (To prevent overrun of engine, torque con-
(Even if the operator makes a mistake in oper- verter, and transmission, to improve durability
ation of the gear shift lever, the transmission and reliability)
does not skip a gear speed. This is to prevent If a symptom of overrun is detected, the rear
overrunning of the engine.) brake is actuated automatically to prevent
2) Neutral safety function overrun even if the engine speed is below the
This circuit prevents the engine from starting if above value.
the gear shift lever is not at the N position, 5) REVERSE safety
even if the starting switch is turned to the The machine will not travel in reverse if the
START position. dump control lever is not at FLOAT and the
(This is a safety circuit to prevent the machine dump body is not completely lowered.
from moving unexpectedly when the engine is (Turnover prevention function)
started.) 6) Speed range limit function when dump body is
3) Directional inhibit function raised
When traveling in reverse at a speed of more After dumping the load, if the body is not com-
than 4.0 km/h, even if the gear shift lever is pletely lowered, shifting up is limited.
operated to D or positions 6 to L, the transmis- If the gear shift lever is at D or 6 - L, the
sion will not be shifted immediately to travel machine starts in F1 and the gear is not shifted
forward. The engine speed is lowered to up until the body is completely lowered.
reduce the travel speed, and when the travel
speed goes below 4.0 km/h, the transmission Self-diagnostic function
is shifted to FORWARD. q The controller carries out self-diagnosis of the
(To prevent overload on power train, to improve system and displays any abnormalities.
durability and reliability) q The details of the self-diagnosis are displayed
on a monitor.
When traveling forward at a speed of more q If any abnormality is detected by the self-diag-
than 4.0 km/h, even if the gear shift lever is nosis function, the abnormality data is trans-
operated to position R, the transmission will mitted to the network and is displayed as an
not be shifted immediately to travel in reverse. action code on the machine monitor. The
The speed range is shifted to N and the engine transmission system caution, warning lamp, or
speed is lowered to reduce the travel speed. alarm buzzer may also be actuated.
When the travel speed goes below 4.0 km/h,
the transmission is shifted to REVERSE.
When starting the engine, if the machine is

already traveling forward or in reverse at a
speed of more than 4.0 km/h, even if the gear
shift lever is operated to a position R, the
machine will not move and the transmission
will be held at N.
When the travel speed goes below 4.0 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
HD465-7R, HD605-7R 11
Transmission controller list of real-time monitoring display contents

With a real-time monitor function of a machine monitor, I can confirm a state of a controller input and
output signal.
Real-time monitoring display items related to transmission controller, and contents displayed when there
is normality are as follows.
No. Item ID number Displayed spec Data contents
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version is output (Soft logic part version)
3 Data version 20224 VERSION (DATA) Software version is output (Soft logic part version)
4 Transmission input axis rotation 31200 T/M SPEED:IN Input axis rotation speed is output
5 Transmission intermediate axis rota- 31300 T/M SPEED:MID Intermediate axis rotation speed is output
tion
6 Transmission output axis rotation 31400 T/M SPEED:OUT Output axis rotation speed is output
7 Fuel level 04201 FUEL SENSOR Resistance-converted value of fuel level sensor
(A_IN_5) is output
8 Fuel level 04201 FUEL SENSOR Input voltage of fuel level sensor (A_IN_5) is out-
put
9 Alternator R 04301 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
10 Torque converter oil temperature 30100 T/C OIL TEMP Torque converter oil temperature (A_IN_1) of oil
temperature value is output
11 Torque converter oil temperature 30101 T/C OIL TEMP Torque converter oil temperature (A_IN_1) of
search voltage value is output
12 Transmission oil temperature 32500 T/M OIL TEMP Transmission oil temperature of oil temperature
value is output
13 Transmission oil temperature 32501 T/M OIL TEMP Transmission oil temperature of search voltage
value is output
14 Steering oil temperature 32701 STRG OIL TEMP Steering oil temperature (A_IN_3) of oil
temperature value is output
15 Steering oil temperature 32702 STRG OIL TEMP Steering oil temperature (A_IN_3) of search
voltage value is output
16 Torque converter oil temperature 32600 T/C OIL PRESS Torque converter oil temperature (A_IN_10) of
pressure ratio voltage value is output
17 Torque converter oil temperature 32605 T/C OIL PRESS Torque converter oil temperature (A_IN_10) of
input voltage value is output
18 Accumulator oil pressure (front) 35500 ACC OIL PRE F Pressure-converted value of front accumulator oil
pressure (A_IN_8) is output
19 Accumulator oil pressure (rear) 35501 ACC OIL PRE R Pressure-converted value of rear accumulator oil
pressure (A_IN_9) is output
20 Accumulator oil pressure (front) 35504 ACC OIL PRE F Voltage sensed by front accumulator oil pressure
(A_IN_8) is output
21 Accumulator oil pressure (rear) 35505 ACC OIL PRE R Voltage sensed by rear accumulator oil pressure
(A_IN_9) is output
22 Solenoid output (H) 31600 ECMV H DIR HIGH clutch of ECMV output direction current is
output
23 Solenoid output (L) 31601 ECMV L DIR LOW clutch of ECMV output direction current is
output
24 Solenoid output (1st) 31602 ECMV 1 DIR 1st clutch of ECMV output direction current is out-
put
25 Solenoid output (2nd) 31603 ECMV 2 DIR 2nd clutch of ECMV output direction current is out-
put
12 HD465-7R, HD605-7R
Data range Remarks

Depending upon software part number
Depending upon software version
Depending upon software version
x1 [min-1] (0 – 32767 [min-1])
---- [Besides the above]
x1 [min-1] (0 – 32767 [min-1])
x1 [min-1] (0 – 32767 [min-1])
x1 [z] (0 – 250 [z])
x.001 [V] (0 – 5 [V])
0:OFF
1:ON
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20 V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [mV] (0.00 – 5.00 [V])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
HD465-7R, HD605-7R 13

3rd clutch of ECMV output direction current is out-
26 Solenoid output (3rd) 31604 ECMV 3 DIR
put
4th clutch of ECMV output direction current is out-
27 Solenoid output (4th) 31605 ECMV 4 DIR
put
REV clutch of ECMV output direction current is
28 Solenoid output (R) 31606 ECMV R DIR
output
Lockup clutch of ECMV output direction current is
29 Solenoid output (Lockup) 31609 ECMV LU DIR
output
30 Angle sensor 32900 ANGLE SENSOR Angle sensor input (A_IN_7) of angle sensor ratio
value is output
Angle sensor input (A_IN_7) of voltage value is
31 Angle sensor 32903 ANGLE SENSOR
output
Brake output (front wheel) direction Brake command amount of brake (retarded) con-
32 33807 BK OUTP DIR F
value troller
Brake output (rear wheel) direction Brake command amount of brake (retarded) con-
33 33806 BK OUTP DIR R
value troller
Throttle modified value is output sent to engine
34 Throttle modified value 36000 THROTTLE MOD
controller
35 Low clutch trigger compensation 38900 TRIGGER MOD L Low clutch trigger compensation value is output
value (all oil pressure mode)
36 High clutch trigger compensation 38901 TRIGGER MOD H High clutch trigger compensation value is output
37 1st clutch trigger compensation value 38902 TRIGGER MOD 1 1st clutch trigger compensation value is output (all
oil pressure mode)
14 HD465-7R, HD605-7R
Data range Remarks

x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [° ] (-25.0 – 25.0 [° ])
x1 [mV] (0.00 – 5.00 [V])
x1 [%] (0 – +100.0 [%])
x1 [%] (0 – +100.0 [%])
x1 [%] (-100.0 – +100.0 [%])
According to the follows hex decimal
Display it in order of follows by eight
AABBCCDD
AA: Low temperature compensation value [x10msec]
BB: Inside temperature compensation value [x10msec]
CC: Normal temperature compensation value [x10msec]
DD: High temperature compensation value [x10msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]

(Every each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HD465-7R, HD605-7R 15

38 2nd clutch trigger compensation 38903 TRIGGER MOD 2 2nd clutch trigger compensation value is output
39 3rd clutch trigger compensation value 38904 TRIGGER MOD 3 3rd clutch trigger compensation value is output
(all oil pressure mode)
40 4th clutch trigger compensation value 38905 TRIGGER MOD 4 4th clutch trigger compensation value is output
(all oil pressure mode)
41 Revolution clutch trigger compensa- 38906 TRIGGER MOD R Revolution clutch trigger compensation value is
tion value output (all oil pressure mode)
42 Clutch FILL switch 38919 FILL HL1234R Every each clutch of FILL SW recognition condi-
tion is output
[H,L,1,2,3,4,R]
16 HD465-7R, HD605-7R
Data range Remarks

AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
[1 (ON), 0 (OFF)] by data to support right under HLR1234R attend H: H Fill switch recognition [1:ON, 0:OFF]
and display L: L Fill switch recognition [1:ON, 0:OFF]
1: One Fill switch recognition [1:ON, 0:OFF]
Example 2: Two Fill switch recognition [1:ON, 0:OFF]
011000: F1 time 3: Three Fill switch recognition [1:ON, 0:OFF]
001001: R2 time 4: FOUR Fill SW recognition [1:ON, 0:OFF]
000000: N time R: R Fill switch recognition [1:ON, 0:OFF]
100010: F4 time
HD465-7R, HD605-7R 17

43 Trigger initial learning flag 38920 TRIG HL1234R Output an early condition of learning flag state of
trigger time every each clutch
[H, L, R, 1, 2, 3]
Display it in order of follows by eight columns of

indication
[HLR123]
H: H flag [1:ON, 0:OFF]
L: L flag [1:ON, 0:OFF]
R: R flag [1:ON, 0:OFF]
1: One flag [1:ON, 0:OFF]
2: Two flag [1:ON, 0:OFF]
3: Three flag [1:ON, 0:OFF]
44 Fill time (L) 41800 FILL TIME L LOW clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
45 Fill time (H) 41801 FILL TIME H High clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
46 Fill time (1) 41802 FILL TIME 1 1st clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
47 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
48 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
49 Fill time (4) 41805 FILL TIME 4 4th clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (R) 41806 FILL TIME R Revolution clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Throttle lower limit value output 44201 THROT LIMIT LO Throttle lower limit value output sent to engine
controller
x0.1 [%] (0 – +100.0 [%])
52 Throttle higher limit value output 44200 THROT LIMIT HI Throttle higher limit value output sent to engine
controller
x0.1 [%] (0 – +100.0 [%])
53 Input signal D_IN_0-7 40905 D-IN--0------7 Input signal condition is output
54 Input signal D_IN_8-15 40906 D-IN--8-----15 Input signal condition is output
55 Input signal D_IN_16-23 40907 D-IN-16-----23 Input signal condition is output
56 Input signal D_IN_24-31 40908 D-IN-24-----31 Input signal condition is output
57 Input signal D_IN_32 40942 D-IN-32 Input signal condition is output

58 Output signal D_OUT_0-7 40949 D-OUT-0------7 ON/OFF output signal D_OUT_0-7 condition.
Display 0 at the time of power supply output setting.
59 Output signal D_OUT_8-15 40950 D-OUT-8-----15 Supports SOL_OUT_8, 9, 10A, 10B, 11A, 11B,
SIG_OUT_0, SIG_OUT_1.
60 Output signal D_OUT_16-23 40951 D-OUT-16----23 Supports SIG_OUT_2, 3, HSW_OUT_0, 1,
BATT_RY_OUT. Not used D_OUT_21 to 23.
18 HD465-7R, HD605-7R
Data range Remarks

Display a learning flag ON/OFF state of a clutch to fall under right
under HLR1234R in [1 or 0]
HLR1234R
1111111 (Finished with all clutches learning)
HLR1234R
0000000 (Unlearned in all clutches)
x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])

*0******: Transmission oil filter clogging D_IN_1: Transmission oil filter switch 1
****1***: Cranking D_IN_3: Emergency escape switch
******0*: Non-operation emergency steering D_IN_4: C terminal signal
******1*: Operation emergency steering D_IN_6: Emergency steering relay
*******1: Shift lever N D_IN_7: Shift lever N
1*******: L fill D_IN_8: Fill signal L
*1******: 4th fill D_IN_9: Fill signal 4th
**1*****: H fill D_IN_10: Fill signal H
***1****: 1st fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
10010000: F1 time
00010010: R1 time
00000000: N time
11000000: F6 time
10000000: Shift lever R D_IN_16: Shift range R
01000000: Shift lever D D_IN_17: Shift range D
00100000: Shift lever 6 D_IN_18: Shift range 6
00000001: Shift lever L D_IN_23: Shift range L
*0******: Lowering of coolant level D_IN_25: Coolant level
**0*****: Clogging of air cleaner D_IN_26: Air cleaner switch
***0****: Operation of main pressure variable valve D_IN_27: Main pressure variable valve pressure switch
****0***: Operation of main oil flow selector valve D_IN_28: Main oil flow selector valve pressure switch
*****0**: Operation of lubricating oil flow variable valve D_IN_29: Lubricating oil flow variable valve pressure switch
* Plane does not use
HD465-7R, HD605-7R 19
Automatic emergency steering system 1
1. Timer Outline
2. Battery If the engine should stop when the machie is travel-
3. Emergency steering oil pressure switch ing, or there is any abnormality in the hydraulic
4. Emergency steering motor pump and the steering circuit oil pressure is
5. Emergency steering pump become below the specifed value, the emergency
6. Steering control valve system automatically 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.
20 HD465-7R, HD605-7R
Relay timer
1. Dial Outline
2. Lock This 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
Set time: 1 seconds the timer, the relay contacts are switched.
HD465-7R, HD605-7R 21
Automatic suspension system 1
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
5. Hydraulic cylinder to the operator and to improve the travel stability.
a For details of the internal mechanism of the
suspension, see Suspension
22 HD465-7R, HD605-7R
Automatic suspension mode selection control

With the front suspension, the mode (damping a When a liner has been installed to the body for
force) is automatically changed according to the HD465 to make it equivalent to the rock body,
travel conditions and load conditions to ensure a the increased load on the springs will affect the
comfortable ride and to improve the travel stability loaded/unloaded judgement in the table below.
of the machine. The control patterns and functions In this case, select the machine model HD605
of the modes (damping force) are as shown in the by the switch for the transmission control sys-
table below. tem.
S: Soft
M: Medium
H: Heard
Set mode
Control pattern Function Content of control Empty Loaded
S M H S M H
Distinguishing To set damping force Internal pressure of front sus-
empty/loaded according to load on pension cylinder is measured
machine and compared with standard
valve
Anti-roll To prevent the chas- This detects the travel speed
sis from rolling when and steering angle, and
turning at high speed switches the mode according to (When
turning)
certain 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) Float)
High speed To improve stability Detects travel speed and
stability when traveling at selects damping force. (No con-
high speed trol when traveling empty)
HD465-7R, HD605-7R 23
Auto suspention solenoid valve
2. Solenoid q 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.
24 HD465-7R, HD605-7R
Retarder control system 1
HD465-7R, HD605-7R 25
Retarder controller
Outline according to the travel conditions and load

The retarder controller has the following functions. conditions such as the load weight, turning,
1. Retarder control braking, etc. sent from various sensors to set
The proportional solenoid valve is controlled the damping force of the front suspension to 1
according to the operating angle of the retarder of 3 levels of SOFT, MEDIUM, and HARD.
control lever and actuates the retarder. 6. ASR Control (if equipped)
2. Overrun prevention and retarder control when The retarder controller detects slips of the right
there is transmission abuse and left drive wheels from their speed and
The retarder controller controls the propor- steering angle and controls the ASR propor-
tional solenoid valve to operate the retarder tional solenoid valve to maintain the speed dif-
according to the command of the transmission ference between both wheels constant.
controller. The wheel slipping at higher speed is braked
and the brake torque is transmitted to the
3. Hoist control wheel rotating at lower speed to improve the
The retarder controllers controls the hoist EPC travel performance.
valve (proportional solenoid valve) and hoist
selector valve (ON/OFF valve) according to the 7. Transmission of network data
position of the dump control lever and actuates 1) The retarder controller transmits the infor-
the dump body. mation of operation of the retarder, float
caution, and operation of the parking
4. Automatic retarder speed control (ARSC)
brake to the machine monitor.
(if squipped)
2) The retarder controller receives informa-
The retarder controller controls the propor-
tion of overrun prevention, retarder com-
tional solenoid valve to control the retarder
mand when there is abuse, etc. from the
braking force and keep the downhill travel
transmission controller.
speed at the speed set with the automatic
retarder travel speed set switch. 3) The retarder controller transmits informa-
tion of reverse inhibition, etc. to the trans-
5. Automatic Suspension Control (if squipped) mission controller.
The retarder controller changes the signals for
the automatic suspension solenoid valve
26 HD465-7R, HD605-7R
Input and output signal
BRC1
Pin No. Signal name Imput/output signal Pin No. Signal name Imput/output signal
1 SUS press sensor (RL) Input 13 ARSC set SW Input
2 Strg potentio Input 14 Retard lever Input
3 Retard oil temp (R) Input 15 Alternator R Input
4 GND (SIG) – 16 Sens PWR Output
5 Retard SW (rear) Input 17 Service brake press SW Input
6 Brake system filter Input 18 Validation SW2 Input
7 SUS press sensor (RR) Input 19 Hoist laver (main) Input
8 Body position sensor Input 20 Hoist laver (SUB) Input
9 – Input 21 GND (Analog GND) –
10 GND (SIG) – 22 Pot PWR Output
11 – Input 23 – Input
12 Memory clear SW Input 24 Validation SW1 Input
BRC2
1 – Output 21 S_NET Input/Output
2 Strg hoist filter SW Input 22 CAN0 L Input/Output
3 Strg hoist lever SW Input 23 CAN1 L Input/Output
4 232C RxD Input 24 *FEW SW Input
5 Brake wear SW (RL) Input 25 – Input
6 – Input 26 – Input
7 ENG oil level SW Input 27 – Input
8 – Output 28 TM & Brake oil level SW Input
9 Body float signal Output 29 GND (pulse GND) –
10 Wheel speed (RR) Input 30 T/M output shaft speed Input
11 – Output 31 GND (S_NET GND) –
12 Can SH – 32 CAN0_H Input/Output
13 Eng oil filter Input 33 CAN1_H Input/Output
14 232C TxD Output 34 GND (232C_GND) –
15 – Input 35 Key SW C (Engine start) Input
16 – Input 36 Brake wear SW (RR) Input
17 Retard cooling filter Input 37 Steering speed Input
18 Stop lamp relay Output 38 Battery requid level SW Input
19 – Output 39 GND (pulse GND) –
20 Wheel speed (RL) Input 40 – Input
BRC3
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
SOL_COM SOL_COM
3 Input 23 Input
(solenois common GND) (solenois common GND)
4 – Output 24 Key SIG Input
5 Hoist EPC valve Output 25 – Output
6 – Output 26 ASR valve (RL) Output
7 Auto SUS SOL1 Output 27 Lever kick out sol Output
8 +24 V for sensor Output 28 F/B cut valve Output
9 Parking brake press SW Input 29 – Input
10 ASR press SW (RL) Input 30 Shut off valve SW Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
SOL_COM (solenois com- 33 GND (controller GND) Input
13 Input
mon GND) 34 Reserve –
14 Key SIG Input 35 – Output
15 ASR shut off valve Output 36 ASR valve (RR) Output
16 Retard valve R Output 37 Auto SUS SOL2 Output
17 Hoist change valve Output 38 – Output
18 BCV relay Output 39 Secondary brake SW Input
19 – Input 40 ASR check SW Input
20 ASR press SW (RR) Input
HD465-7R, HD605-7R 27
Retarder control function

Retarder control system diagram
Retarder lever control

q The operating angle of the retarder lever is
detected by the potentiometer and a current
corresponding to this is output to the propor-
tional solenoid valve to actuate the retarder.
Overrun prevention and retarder control when

there is transmission abuse
q The retarder controller controls the propor-
tional solenoid valve to operate the retarder
according to the command of the transmission
controller.
28 HD465-7R, HD605-7R
Relationship between retarder lever potentiometer and output to proportional solenoid valve
A: To improve the initial response of the propor-

tional solenoid reducing valve, the output (trig-
ger output) is set to a high value.
B: To operate the hydraulic equipment smoothly
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 release the hydraulic pressure smoothly in
the low pressure range, the output is set to a
low value.
HD465-7R, HD605-7R 29
Hoist control function

Hoist control system diagram
1. Hoist control function 3. Body seating speed control

When the engine is running, the EPC valve When the body is lowered to near the seat, the
(proportional solenoid valve) and selector open area of the EPC valve is reduced to con-
valve are controlled according to the operation trol the lowering speed of the body and reduce
of the dump control lever and operate the the seating shock.
dump body.
2. Lever positioner function

The dump control lever has four positions:
RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the
RAISE position, the dump body is raised, and
when the top of the dump body reaches the set
position of the body position sensor, the lever
is returned to the HOLD position.
If the lever is kept at the RAISE position, the
RAISE output continues to be given.
30 HD465-7R, HD605-7R
4. Control when starting switch is turned to 4) While running the engine at low idle, raise
ON, OFF, or START the body and float it at the maximum
Starting switch at ON: height, and then lower it to the seat.
The output is set to HOLD, regardless of the Repeat this operation 10 times.
position of the lever. 5) While running the engine at high idle,
If the engine is not started, even if the hoist raise the body and float it at the maximum
lever is operated, the condition remains at height, and then lower it to the seat.
HOLD. Repeat this operation 10 times.
Starting switch at OFF:
The hoist valve is closed and the dump body is
held in position regardless of the position of the
lever.
Engine started:
Immediately after the engine is started, the out-
put is set to HOLD, regardless of the position
of the lever.
After the lever is moved to the HOLD position,
it becomes possible to carry out normal opera-
tions.
5. Reverse inhibit function

The retarder controller judges if it is permissi-
ble to travel in reverse or not, and transmits the
result of the judgment through the network to
the transmission controller.
"FLOAT OUTPUT" or "SEATED" and "LEVER
NOT RAISED" o Reverse travel permitted
"NOT FLOAT OUTPUT" and "NOT SEATED"
o r " L E V E R R A I S E D " a n d " S E AT E D " o
Reverse travel prohibited
6. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body
cylinder stopper condition.
After adjusting the installation of the body

potentiometer 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) While the body is seated completely, run
the engine and set the lever to HOLD and
then to FLOAT, and check that the float
caution lamp goes off.
2) Raise the body and keep the lever in the
RAISE position until the cylinder touches
the stopper. After the cylinder touches the
stopper, keep the lever in the RAISE posi-
tion 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.
HD465-7R, HD605-7R 31
Dump control lever
32 HD465-7R, HD605-7R
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
HD465-7R, HD605-7R 33
Function
q When lever (1) is operated, rod (18) moves up
or down according to the amount the lever is
operated, and rotates potentiometer (16).
q 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.
q 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
q 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 actuation of mechanical detent)
q 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 protru-
sion (a).
q 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).
q Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and
protrusion (b) of rod (19), so the lever is held at
the FLOAT position.
34 HD465-7R, HD605-7R
2. Dump lever FLOAT canceled 4. Dump lever operated to RAISE

q When lever (1) is returned from the FLOAT q When RAISE rod (18) is pushed by lever (1)
position, it is pushed down by a force greater and moves down, ball (14) contacts protrusion
than the holding force of rod (19), detent spring (a) of rod (19) during the stroke. (Before start
(20), retainer (13), and ball (14). of actuation of mechanical detent)
q When rods (18) and (19) are pushed in further,
3. Dump lever operated to LOWER ball (14) is being held by detent spring (20).
q When lever (1) is operated further from the While pushing retainer (13) up, it escapes to
FLOAT position, it moves to the LOWER posi- the outside, and rod (19) passes over protru-
tion. sion (a).
q Rod (18) is pushed up by the spring (4) in q When this happens, rod (2) on the opposite
accordance with the amount lever (1) is oper- side is pushed up by spring (4).
ated. q When an electric current is flowing to solenoid
q 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 contact with bushing (8).
interconnected, so a voltage matching the up q As a result, rod (2) is held at the pushed up
or down movement of the rod is output from position, so even if the lever is released, it is
potentiometer (16). held at the RAISE position.
5. Dump lever RAISE canceled

q When lever (1) is returned from the RAISE
position, 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.
HD465-7R, HD605-7R 35

© 2006 KOMATSU
All Rights Reserved
36 HD465-7R, HD605-7R
SEN02301-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Payload meter (Card type) .......................................................................................................................... 2
HD465-7R, HD605-7R 1
Payload meter (Card type) 1

Structure of system
1. Shift lever neutral detection switch (relay) Outline

2. Body FLOAT signal (retarder controller) q A dump truck is supported by 4 suspension
3. Clinometer cylinders. By measuring the total of the loads
4. Pressure sensor (for front left) on each cylinder, it is possible to know the
5. Pressure sensor (for front right) mass on 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
14. Fuse (for controller) engine was turned ON/OFF, time of occur-
15. Memory card rence/cancellation of abnormalities or warn-
16. Travel signal sensor ings, and other data of each transportation
17. RS232C output cycle are automatically saved in memory.
(PC cable communication) socket These data can be later transmitted to a PC or
18. Battery charge signal (alternator terminal R) 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.
2 HD465-7R, HD605-7R
Block diagram of payload meter
q If a dump truck having the VHMS controller is

equipped with the payload meter (having
VHMS) optionally, the payload meter (card
type) cannot be mounted.
q For setting procedure of payload meter (card
type) when it is installed for the first time,
replaced or removed, see "Testing and adjust-
ing".
HD465-7R, HD605-7R 3
Principle of calculation
1. Outline
A dump truck is supported by 4 suspension
cylinders. 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 cyl-

inder,
PB PT
Therefore, the load can be calculated as fol-
lows.
W = PBST
4 HD465-7R, HD605-7R
2. Measurement of mass when empty 5. Detecting distance, travel speed

(Calibration) The travel speed and distance are detected
Drive the empty dump truck at a speed of from the travel signal sensor on the truck.
about 10 km/h for about 30 seconds, and then a Travel signal sensor:
measure the average load and use it as the Transmission output speed sensor
mass when empty.
The reason why the mass is measured while
the dump truck is traveling is that the sliding
resistance of the suspension cylinders must be
averaged by extracting and retracting the cylin-
ders 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 gear shift 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
measured mass is different from the mass
measured on a level ground. To solve this
problem, the longitudinal inclination of the
dump truck is measured and the measured
mass is corrected according to the inclination
angle. (Correction range of inclination angle: ±
5°)
HD465-7R, HD605-7R 5
Features of each device

1. Payload meter
Payload meter receives signals from the
pressure sensors, clinometer, body float sen-
sor, gear shift 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 communi-
cation cable is not connected to a PC
or when there is defective connection.
a When not inserting or removing mem-

ory card (9), always keep cover (10)
closed.
6 HD465-7R, HD605-7R
Left face
q Details of switches on left face
No. Name Type Remarks
1. Load mass compensation trimmer Rotary volume –20% – +20%

(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.
HD465-7R, HD605-7R 7
q Table of model selector code
No. of model selector switches Model
2 HD465-7 STD Small-tire Komatsu engine
3 HD325-7 STD Large-tire Komatsu engine
A HD605-7 STD Large-tire Komatsu engine
q 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 set-
ting operations 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 (bot-
tom)
Calibration, data all clear, card dump,
time, date setting operations only are pos-
sible.
8 HD465-7R, HD605-7R
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 dis-
play will switch after several seconds to iii) Normal operation display.
HD465-7R, HD605-7R 9
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 loading, Mass display and esti-

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

Stopped N FLOAT Mass display
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 mea-
sured 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
Operation 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 over-
load.
10 HD465-7R, HD605-7R
V) Content of memory (for details, see Operation

and maintenance manual)
a) Cycle data
a The period between one dumping opera-
tion 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 mem-
ory 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
HD465-7R, HD605-7R 11
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
12 HD465-7R, HD605-7R
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.)
HD465-7R, HD605-7R 13
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
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 0-9.99999
Mass on spring (empty) t (Metric ton) 0-6553.5
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
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 0-9.99999
Mass on spring (empty) t (Metric ton) 0-6553.5
(Calibration value)
Trimmer gain value Integer 0.7500 –1.2500
Load mass t (Metric ton) 0-6553.5
Backup battery voltage V 0-25.5
The above data items a) – g) are retained even when the power is switched OFF.
14 HD465-7R, HD605-7R
vi) Forced display of aggregate load mass, total x) Service check mode
number of cycles By operating the switches of payload meter ,
Forced display of existing abnormalities and it is possible to forcibly carry out display, set-
warnings ting, and correction of the following items.
By operating the TOTAL/SFT switch of payload
meter II, it is possible to carry out forcible dis- a) Detailed calibration data display
play of these items. The display shows the date, suspension
For details, see the Operation and Mainte- pressure, etc. when the latest calibration
nance Manual. was carried out.
vii) Operator check mode b) Detailed load mass calculation data dis-
By operating the switch of payload meter , it play (analog data)
is possible to carry out the following items. The display shows the suspension pres-
For details, see the Operation and Mainte- sure and machine angle used when calcu-
nance Manual. lating the present load mass.
a) Memory card dump
b) Data all clear c) Memory card dump (service area)
c) Abnormality, warning exists/cancelled, This writes all the data displayed for Items
input signal condition display 6-6 and 6-7 to the memory card inserted in
d) Machine ID setting the machine.
e) Open ID setting
f) Limit speed setting a This function is available only when the
g) Option code setting No. 5 switch on the left side of the control-
h) Time, date correction ler (memory card use switches) is set for
"Use"
viii) Dimming of display portion
It is possible to adjust the brightness of the d) Data all clear (service area)
payload meter display portion to 10 levels This forcibly deletes all the calibration data
with the LIGHT/INC switch. and analog data, except for the latest cali-
bration data.
ix) Downloading saved data
It is possible to download any data recorded in a Before clearing the data, always download
payload meter to a PC through a cable the data to a PC or carry out a) Card
(ANSI/E1A RS-232C). dump.
For details, see the PC software manual pro-
vided by Komatsu. e) Input signal condition display
This displays some of the signal condi-
tions for the sensors input to payload
meter and the present recognition con-
dition of the payload 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
operation with the machine unloaded. Do
not carry out the operation unless neces-
sary.
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 (%)
HD465-7R, HD605-7R 15
h) Load mass fixed display and cycle data record-

ing, load mass value setting
(1) Load mass fixed display
When displaying the load mass in the
range shown in the table below, it is possi-
ble to input and correct to set the display
for the load mass when loading is com-
pleted (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

setting
This is used to input and correct the values to
set the travel distance recognized as comple-
tion 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:
HD325-7
1
480 – 1,480 [ x 100 t]
HD405-7
HD465-7E0
t
690 – 1,690 [ x 100
]
HD605-7E0
HD465-7R
t
690 – 1,690 [ x 100
]
HD605-7R
16 HD465-7R, HD605-7R
k) Zero ton display range setting

This is used to input and correct the val-
ues 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 val-
ues to set the lamp display load mass
range when displaying the load mass.
Possible set range:
Lamp 1 (green) A : 50 – 255
Lamp 2 (yellow) B : A – 255
Lamp 3 (red) C : B – 255
The set value is displayed as a pro-

portion (%) of the correct load mass.
t Of the service check mode functions, the

following functions can be downloaded to
a PC using the PC downloading software
provided by Komatsu.
q Calibration data
q 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
wh en th e br a k e l o c k i s O N, a n d o n
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 operated 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.
HD465-7R, HD605-7R 17
18 HD465-7R, HD605-7R
(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 dur- Hour and minute for date
ing 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:
8 x 98kPa P'RR (Rear right) XXX.X
t Mass on front axle Less than 100 t:

9
(= x/4DF2 (P'FL+P'RL)) XX.X
t Mass on rear axle More than 100 t:
10 XXX.X
(= x/4DR2 (P'RL+P'RR))
Appears when value is
Angle of tilt when CAL was negative
11 x O
180 rad carried out
(–) 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.
16 and 10.
according to calibration
17 CALO flashes
Returns to 1. and
repeats sequence
All displayed values are rounded to
the value given.
HD465-7R, HD605-7R 19
(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 3 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
during the display in Steps 1. or 2., the display 4 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
will return to CHEC. (End) 5 x 98kPa P'RR (Rear right)
t Mass on front axle Suspension
6 pressure less than
(= x/4DF2 (P'FL+P'RL))
100 x 98 kPa: XX.X
t Mass on rear axle More than 100 x 98 kPa:
7
(= x/4DR2 (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.
20 HD465-7R, HD605-7R
(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),
When the memory card dump operation is and when the data all clear operation is com-
completed, it will return automatically to the pleted, it will return automatically to the CHEC
CHEC display. (End) display. (End)
If it is desired to stop the memory card dump If it is desired to stop the data all clear opera-
operation when the display is Cd : dP, press tion when the display is A : CLE, presss
MODE switch (2), and the display will return to MODE witch (3), and the display will return to
CHEC without performing the memory card CHEC without performing the data all clear
dump operation. operation.
The memory card dump function can be used a Before clearing the data, download the
only when the No. 5 switch (memory card use necessary data to a PC or carry out the
switch) on the left side of the controller is set to card dump operation in Item (c).
"Use".
HD465-7R, HD605-7R 21
(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
(2-g) Digital spare input 1 signal condition
1. Set to CHEC display, then press TOTAL/SFT
switch (1) and CAL/CLR switch (2) at the same
Hi:C7 : oo
time for at least 2 seconds.
Lo: C7 : — —
Display: S : CHE
O
(2-h) Digital spare input 2 signal condition
2. Every time CAL/CLR switch (1) is pressed, the
Display: C8 : XX (lights up for 3 seconds)
display changes in the order shown below.
X.X .... Same as C7
O
(2-a) Parking brake, brake lock switch signal condi-
(2-i) Travel speed display
tion [HD1200-1]
Display: C9 : XX
X.X .... Travel speed (km/h)
O
Either one ON:CL : oo
(2-j) Travel distance display
Both OFF:CL : — —
O
Travel distance with machine in present
(2-a’) Shift lever position signal condition
condition (empty or loaded) for that cycle
[except HD1200-1]
Display: C1: XX (lights up for 3 seconds)
XXXX .... (m)
"N":CL : oo
* If the value goes above 9999m, the display
Except "N":CL : — —
starts again from 0.
O
O
(2-b) Dump lever position signal condition
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
22 HD465-7R, HD605-7R
From previous page ( f ) Operation for performing forced initialization

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
Invariable May change switche (11), TOTAL/SFT switch (2) and
according to
N signal when LIGHT/INC switch (3) at the same time for at
O dumping
least 2 seconds.
(2-l) Machine condition time display shown below Display: :
Every time CAL/CLR switch (1) is pressed,

the display advances one place in order from 2. Press CAL/CLR switch (1) for at least 2 sec-
a) to f). onds.
The display becomes : (lighted up)
a Empty traveling S1 : (2 seconds),
b Empty stopped S2 : and when all the data is completely cleared, it
c Loaded traveling S3 : automatically displays F.CAL. (End)
d Loaded stopped S4 : After that, it carries out the process from 10.3.
e Dumping S5 :
If it is desired to stop the forced initialization
f Loading S6 :
operation when the display is : ,
press MODE switch (4), and the display will
return to CHEC without performing the forced
initialization 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 dur-

ing the display in Steps 1. or 2., the display will
return to CHEC. (End)
HD465-7R, HD605-7R 23
(g) Operation for setting extra load mass when (h) Operation for setting load mass fixed display
loading and cycle data record value
1. Set to CHEC display, then press TOTAL/SFT 1. Set to UP : XX display, then press CAL/CLR
switch (1) and LIGHT/INC switch (2) at the switch (4)
same time for at least 2 seconds.
Display: PL : XX (present set value)
Display: S.5EL
If it is necessary to correct the setting, press
2. Press CAL/CLR switch (3). LIGHT/INC switch (2) and correct.
Display UP : XX present set value: for+: X
When the correction operation is completed,
for–: – X
press MODE switch (1) at any time to return to
If it is necessary to correct the setting, press
the CHEC display. (End)
LIGHT/INC switch (2) and correct.
3. When the correction operation from Step 1. is

completed, press MODE switch (4) at any time
to return to the CHEC display. (End)
24 HD465-7R, HD605-7R
( i ) Operation for setting loading completion recog- ( j ) Operation for setting loading start recognition
nition travel distance load mass
1. Set to PL: XX display, then press CAL/CLR 1. Set to O.SEL display, then press CAL/CLR
switch (4) switch (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 set- If it is necessary to correct the set-
ting for the units, press LIGHT/INC ting for the tens, press LIGHT/INC
switch (2) and correct. switch (2) and correct.
3. Press CAL/CLR switch (4). 3. Press CAL/CLR switch (4).

If it is necessary to correct the set- If it is necessary to correct the set-
ting for the tens, press LIGHT/INC ting for the hundreds, press LIGHT/
switch (2) and correct. INC switch (2) and correct.
4. Press CAL/CLR switch (4) again. 4. Press CAL/CLR switch (4) again.
If it is necessary to correct the setting If it is necessary to correct the set-
for the hundreds, press LIGHT/INC ting for the thousands, press LIGHT/
switch (2) and correct. INC switch (2) and correct.
5. If CAL/CLR switch (4) is pressed again, the 5. If CAL/CLR switch (4) is pressed again, the
display will return to XXX, so it is possible to display will return to Step 3, so it is possible to
correct the units again. correct again.
6. When the correction operation from Step 1. is 6. When the correction operation from Step 1. is
completed, pressMODE switch (1) at any time completed, press MODE switch (1) at any time
to return to the CHEC display after displaying to return to the CHEC display. (End)
O.XXX (input value). (End)
If it is impossible to set the input values even If it is impossible to set the input values even
when MODE switch (1) is pressed, it displays when MODE switch (1) is pressed, it returns to
O.XXX (input value) and returns to Step 2.. Step 1.
HD465-7R, HD605-7R 25
(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 set-
ting, press LIGHT/INC switch (2) and
correct.

26 HD465-7R, HD605-7R
( l ) Operation for setting display range of external 6. Press CAL/CLR switch (4) again.
display lamps
Display: E.XXX
(present value of lamp 5)
If it is necessary to correct the dis-
play range for lamp 5, press LIGHT/
INC switch (2) and correct.

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
4. Press CAL/CLR switch (4) again.

Display: C.XXX
5. Press CAL/CLR switch (4) again.

Display: d.XXX
HD465-7R, HD605-7R 27
2. Self-diagnostic function
The controller always observes the condition of the sensors and outputs, and if any abnormality occurs,
it displays an error message.
Error message display
Order Error code display

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
1 Dump lever at position — b-FL ON All flash When [for HD1200-1]
other than FLOAT removed When parking
(except when dumping) brake or brake
lock is ON
b-FL ON — When [for HD1200-1]
removed When parking
brake or brake
lock is OFF
2 Memory card — Cd flashes — When Removal detec-
removed removed tion only for card
dump
3 Drop in backup battery Defective contact F-09 flashes — When Except during
voltage or voltage below removed loading
2.7 V
4 Cycle data memory See (*1) See (*1) — See (*1) Except during
FULL loading
Engine ON/OFF data
memory FULL
Abnormality, warning
data memory FULL
Aggregate load mass,
number of cycles data
memory FULL
5 Disconnection in Output below 2 V F-18 flashes All flash When When engine is
terminal R when engine is removed running
running
6 Abnormality in sensor Output is less than F-20 flashes All flash When Any time
power source (18 V) 15 V and power removed
source voltage is
more than 20 V
7 Short circuit with Suspension pres- F-21 flashes All flash When Any time
ground, disconnection sure sensor input removed
in front left suspension signal is 0 kPa or
pressure sensor system below
8 Short circuit with F-22 flashes
ground, disconnection
in front right suspen-
sion pressure sensor
system
in rear left suspension
pressure sensor system
in rear right suspension
pressure sensor system
28 HD465-7R, HD605-7R
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)
HD465-7R, HD605-7R 29
Order Error code display

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

(000-019) stopped while problem
occurs
Records External display lamps
(000-041) actuated as follows
Applicable lamp
(000-042)
Machine stopped:
Always ON
(000-043) Machine traveling: OFF
Other lamps during load-
ing: Specified actuation
(000-044) Other than loading
Machine stopped: Flashes
Machine traveling: OFF
(000-045)
Records (000-071) —
(000-073)
(000-080)
(000-081)
(000-091)
(000-092)
(000-093)
(000-094)
(000-095)
(000-096)
(000-097)
(000-098)
(000-099)
HD465-7R, HD605-7R 31

© 2006 KOMATSU
All Rights Reserved
32 HD465-7R, HD605-7R
SEN02302-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

VHMS controller related.................................................................................................................................. 2
Sensors, switches ......................................................................................................................................... 26
HD465-7R, HD605-7R 1
VHMS controller related 1

a For details of basic precautions, outlines, see
"Testing and adjusting".
VHMS controller
a 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
controller. It also gives commands for transmitting
the accumulated data through the communications
satellite.
2 HD465-7R, HD605-7R
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 z
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 com-
munications satellite to the computer center.
HD465-7R, HD605-7R 3
Payload meter (having VHMS)

System configuration
4 HD465-7R, HD605-7R
Outline q The payload meter (having VHMS) cannot be

q A dump truck is supported by 4 suspension installed to a dump truck which is not equipped
cylinders. By measuring the total of the loads with the VHMS controller or which is equipped
on each cylinder, it is possible to know the with the VHMS controller and payload meter
mass on the springs of the dump truck. (card type).
The measurement of the load mass is obtained
by calculating the difference between the mass
when empty and the mass when full.
Payload meter displays the load mass calcu-
lated as above on the monitor screen and dis-
plays the load level on the 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.
q 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 fol-
lowing 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
statistically processing the data sampled
during the travel from the loading area to
the dump area (New method).
q The VHMS controller executes the functions of

the payload meter and saves the data of each
transportation cycle. It displays, sets, and
operates 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
necessary 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
memory card. If it is installed, however, have
the machine monitor and VHMS controller rec-
ognize that it will execute the functions of the
payload meter, by using rotary switch 2 of the
transmission controller and VHMS initial set-
ting tool.
For setting procedure, see Testing and adjust-
ing, "Initial setting of payload meter", and
"Replacing parts".
HD465-7R, HD605-7R 5
Electric circuit diagram

See Troubleshooting, Troubleshooting of VHMS
controller system (VHMS mode).
Principle of measurement
1. Outline
2. Measurement of mass when empty

(Calibration)
q For measurement of mass when empty,
see Payload meter (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 gear shift 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 longitudinal 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
measured mass is different from the mass
measured on a level ground. To solve this
problem, the longitudinal inclination of the
dump truck is measured 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
information.
a Travel signal sensor:
Transmission output shaft speed sensor
6 HD465-7R, HD605-7R
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
payload meter (card type) is installed for the
first time
2. When the payload meter (having VHMS) or
payload meter (card type) is removed
3. When the VHMS controller or transmission
controller is replaced
4. When setting of VHMS controller is changed
Setting with VHMS initial setting tool (*2)
Set position
of rotary Date
VHMS PLM- Time
Setting of payload meter switch 2
controller (card (SW2) of Variation Time
type) Model Serial No. difference
transmission code
controller (*1) Summer
time
Not
F – – – –
Payload meter function is not installed Not
installed installed
Installed B ST
HD465
Payload meter func- Not Set
tion is installed VHMS Installed 9 or –7 PV
Payload 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 wir- 4. The storage place of the data file made by the
ing of the payload meter but there are the following download software is not found.
problems, check the above setting again. a Wrong setting of the model and serial No.
1. Items related to the payload meter are not dis- with the VHMS initial setting tool.
played on the machine monitor.
5. Data cannot be downloaded.
"The payload is not displayed when the
a Wrong setting of the model, serial No.,
machine is loaded and stopped", "There are
and variation code with the VHMS initial
not the manus related to the payload meter on
setting tool.
the match marks", etc.
a Wrong setting of rotary switch 2 (SW2) of 6. Date and time of the downloaded data are
transmission controller wrong.
a Wrong setting of the date and time with
2. While the payload meter (having VHMS) is not
the VHMS initial setting tool.
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 (having VHMS) is set,
the payload does not match to the lighting con-
dition of the red lamp of the outside indicator
lamps.
a Wrong setting of the model and serial No.
with the VHMS initial setting tool.
HD465-7R, HD605-7R 7
Basic functions of payload meter 7. Setting of OFFSET range

For details, see Operation and Maintenance Man- This function is used to adjust the calculated
ual. load mass by a set amount.
Various setting functions 8. Selection of method of entering saved load

(Service functions) mass
1. Setting of travel distance to recognize com- This function is used to select either of the fol-
pletion of loading lowing methods of entering the hauled load
When the dump truck travels 160 m from the mass.
loading area, the payload meter judges that 1) Save the load mass when the dump lever
the loading operation is finished. If the dump is moved from the FLOAT position to
truck is unloaded before it travels 160 m, the another position in a dump area (This
payload meter does not judge that the dump method is set when shipped).
truck is unloaded and the cycle data is not 2) Input and save the hauled load mass by
completed at this time. This function is used to statistically processing the data sampled
change the travel distance to recognize com- during the travel from the loading area to
pletion of loading when the distance between the dump area.
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 forcibly with the mea-
sured 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
maximum travel speed for the machine control
system.
5. Setting of load mass to recognize start of

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

cator 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.
8 HD465-7R, HD605-7R
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)".
HD465-7R, HD605-7R 9
1. Setting of travel distance to recognize com- 2. Correction of calculation of payload

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

Select "EMPTY WEIGHT" or "LOADED
WEIGHT".
q [ ] switch: Enter the selection.
q [ ] switch:
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 HD465-7R, HD605-7R
ii) Check that measurement of the iv) Check the input value.
weight of the empty dump truck has
been completed.
q [>] switch: Select "YES".

q [<] switch: Select "NO".
q [
] switch: q [ ] switch: 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.
q [ ] switch:
iii) Input the measured weight of the
empty dump truck.
q [ ] switch:
After getting ready for drive,
press this switch and start
driving the dump truck.
q [>] switch: q [ ] switch:
Number at cursor moves for- Return to the screen for input-
ward. ting values.
q [<] switch: Drive the dump truck for about 3 min-
Number at cursor moves back- utes (at a speed higher than 8 km/h)
ward. to enter the relationship between the
q [ ] switch: Enter number at cursor. weight of the dump truck and the sus-
q [ ] switch: pension pressure under that weight.
Return to the largest position
of the number to input the
value again. If this switch is
pressed again, inputting of the
value is stopped and the previ-
ous screen appears.
q Inputtable range
HD465-7:
43.6 [t] (Operating weight ± 13%)
(metric ton)
HD605-7:
(metric ton)
HD465-7R, HD605-7R 11
vi) Display the progress of measurement. i) Select "LOADED WEIGHT".

For the method of displaying the fol-
lowing screen, see the steps up to the
above step.
q [
] switch:
Stop measurement and return
to the previous screen.
As measurement is executed, the q [>], [<] switches:
number of [ ] increases. When mea- Select "EMPTY WEIGHT" or
surement is finished, the next screen "LOADED WEIGHT".
appears automatically. q [ ] switch: Enter the selection.
3) Load the dump truck to measure the q [ ] switch:
weight 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.
(SHORT): short ton
ii) Check that measurement of the weight
of the fully loaded dump truck has
been completed.
q [ ] switch:
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 q [ ] switch:
loaded dump truck and drive the dump Check that measurement has
truck for about 3 minutes. been completed and go to the
next step.
q [ ] switch:
12 HD465-7R, HD605-7R
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.
[>] switch:
q q [] switch:
Number at cursor moves for- After getting ready for drive,
ward. press this switch and start
q [<] switch: driving the dump truck.
Number at cursor moves q [ ] switch:
backward. Return to the screen for input-
q [ ] switch: Enter number at cursor. ting values.
q [ ] switch: Drive the dump truck for about 3 min-
Return to the largest position utes (at a speed higher than 8 km/h)
of the number to input the to enter the relationship between the
value again. If this switch is weight of the dump truck and the sus-
pressed again, inputting of the pension pressure under that weight.
value is stopped and the previ- vi) Display the progress of measurement
ous screen appears. (Fig. 9).
a 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.
q [] switch:
Stop measurement and return
to the previous screen.
As measurement is executed, the
number of [ ] increases. When mea-
surement is finished, the next screen
appears automatically.
q [<] switch: Select "YES".

q [>] switch: Select "NO".
q [ ] switch: Enter.
HD465-7R, HD605-7R 13
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 direc-
tion) on the same position and use the
average value as the standard level.
i) Enter value of (F).
q [ ] switch:
If the load is dumped with the dump lever,
the menu screen appears automatically.
If the load is dumped normally, correction
is finished.
q [ ] switch: Enter the flashing value.

q [ ] switch:
The current standard level value is
displayed on the upper line. The cli-
nometer value (F) at the current posi-
tion 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).
q [ ] switch: Enter the flashing value.

q [ ] switch:
displayed on the upper line. The cli-
nometer value at the current position
flashes. Enter it when it is stabilized.
14 HD465-7R, HD605-7R
iv) Enter the standard level value. 4. Setting of criterion of maximum travel speed
q [<] switch: Select "YES". Input a criterion of the maximum travel speed
q [>] switch: Select "NO". by pressing the following switches.
q [ ] switch: Enter. q [>] switch:
Number at cursor moves forward.
q [<] switch:
Number at cursor moves backward.
q [ ] switch: Enter number at cursor.
q [ ] switch: Stop inputting number.
The setting range is 0 – 99 km/h (0 – 62 MPH).
(Default: 99 km/h)
HD465-7R, HD605-7R 15
5. Setting of payload to recognize start of load- 6. Setting of indication range of outside indi-
ing cator lamps
Input a payload to recognize start of loading by Input an indication range of the outside indica-
pressing the following switches. tor lamps by pressing the following switches.
q [>] switch: q [>] switch:
Number at cursor moves forward. Number at cursor moves forward.
q [<] switch: q [<] switch:
Number at cursor moves backward. Number at cursor moves backward.
q [ ] switch: Enter number at cursor. q [ ] switch: Enter number at cursor.
q [ ] switch: Stop inputting number. q [ ] switch: Stop inputting number.
The setting range is 0 – 25.5%. a The setting range is 0 – 130% of the load
(Default: 15%) capacity.
a This function does not assure the operation Set (A) (Yellow lamp) higher than (G)
because of the contrary phenomena shown (Green lamp) and set (R) (Red lamp)
below. higher than (A) (Yellow lamp), however.
q If the value is reduced, start of loading
may be recognized wrongly.
q If the value is increased and a loader hav-
ing a small-capacity bucket is used, the
forecast function of the outside indicator
lamps and the MMS communication may
not operate normally.
16 HD465-7R, HD605-7R
7. Setting of OFFSET range 8. Selection of method of entering saved pay-

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

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

q [>] switch: Select "NO".
q [ ] switch: Enter.
HD465-7R, HD605-7R 17
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 com-
munication 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 sys-
tem 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 auto-
matically.
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 communi-
cation.
q Specifications of RS232C connection
Baud rate: 9600 bps
Data length: 8 bits
Stop bit: 2 bits
Parity: Not applied
Flow control: Not executed
q Connection of RS232C (communication line) (3-wire method)
q Selecting wiring harness for downloading/automatic transmission/MMS communication
18 HD465-7R, HD605-7R
q Distinction of communication control codes

The transmitting side transmits data as explained below so that the data in a communication from begin-
ning 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
HD465-7R, HD605-7R 19
q 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.
20 HD465-7R, HD605-7R
q 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 dis-
tinction 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 con-
troller.
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 transmis-
sion.
Transmission of load mass, estimated load mass, and suspension pressure

When mass of 1 bucketful is recognized.
HD465-7R, HD605-7R 21

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

sion.
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 transmit-
ted automatically.
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
22 HD465-7R, HD605-7R

sion.
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
finishes transmission of the real-time data. When the key is turned to the OFF position, trans-
mission 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.
HD465-7R, HD605-7R 23
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)
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
(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
24 HD465-7R, HD605-7R

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 seconds. If this condition is repeated 10 times, the VHMS controller stops transmis-
sion.
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
HD465-7R, HD605-7R 25
Sensors, switches 1
Engine speed sensor
1. Magnet Function
2. Locknut q The engine speed sensor is installed to the
3. Wiring harness ring gear of the flywheel housing. It uses the
4. Connector rotation of the gear teeth to generate a pulse
voltage and transmits a signal to the transmis-
sion controller.
26 HD465-7R, HD605-7R
Accelerator sensor
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
q This is installed under the operator’s cab. The q This is installed under the operator’s cab.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator 2 (No. 5 pin) is connected to the ground; when
pedal is depressed, the movement is passed the accelerator pedal is depressed, signal 3
through the link and rotates the shaft of the (No. 6 pin) is connected to the ground.
potentiometer inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3
pins of the potentiometer. A voltage signal cor-
responding to the angle of the accelerator
pedal is sent from the No. 2 pin to the engine
controller.
HD465-7R, HD605-7R 27
Retarder oil temperature sensor

Steering oil temperature sensor
1. Thermistor Function
2. Plug q The retarder oil temperature sensor is installed
3. Wiring harness on the retarder pipe. It converts a temperature
4. Connector change into a change of thermistor resistance,
and transmits a signal to the transmission con-
troller. The transmission controller transmits
the signal via the network to the machine mon-
itor panel, and the machine monitor panel dis-
plays a temperature level. The temperature
level displayed on the monitor panel reaches a
predetermined position, the lamp flashes and
the warning buzzer sounds.
q The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor
portion detects the temperature, and when the
oil temperature goes above the specified level,
the warning lamps lights up and a message is
displayed on the character display of the mon-
itor panel.
28 HD465-7R, HD605-7R
Coolant level sensor
1. Float Function
2. Sensor q This sensor is installed to the top of the radia-
3. Connector tor, and when the coolant level goes below the
specified level, the float goes down and the
switch goes OFF. The maintenance caution
lamp lights up and the character display shows
message to warn of abnormality.
HD465-7R, HD605-7R 29
Fuel level secsor
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according to the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level. When the display of the monitor panel
reaches a certain level, a warning lamp
flashes.
30 HD465-7R, HD605-7R
Transmission oil filter clogging sensor
1. Body Function
2. Tube q This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A : Low pressure pickup port side and high-pressure side reaches the speci-
B : High pressure pickup port fied pressure, the switch goes OFF. The main-
tenance 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 pis-

ton type
HD465-7R, HD605-7R 31
Air cleaner clogging sensor
1. Indicator Function
2. Spring q The air cleaner clogging sensor is installed to
3. Adapter the 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 message to warn of the abnormality.
32 HD465-7R, HD605-7R
Body positioner sensor
1. Bearing Function
2. Brush Assembly q The body position sensor is installed to the
3. Connector rear of the chassis. When the angle of the
dump body changes, the shaft rotates through
the link installed to the dump body, and the
dump body angle is detected.
HD465-7R, HD605-7R 33
Accumulator oil pressure sensor
1. Sensor Function
2. Connector q The accumulator oil pressure sensor is
installed to the accumulator piping on the right
side of the machine and its sensor section
senses the oil pressure. If the oil pressure low-
ers below the set level, the warning lamp lights
up and the message is indicated on the char-
acter display of the monitor panel.
Steering oil pressure switch (for auto emergency steering system)
1. Piston Function
2. Body q The steering oil pressure switch is installed to
3. Switch the steering and hoist piping. While the engine
4. Connector is running, if the steering circuit oil pressure
lowers below the set level, the steering oil
pressure switch operates the electric pump to
secure the oil pressure for steering.
34 HD465-7R, HD605-7R
Tilt switch
1. Magnet Function
2. Plate q If the chassis tilts to the left or right, the disc
3. Gasket magnet moves to the left or right. If the chas-
4. Print card sis tilts into the roll-over danger range, either
5. Bracket the left or right switch is turned OFF. If the
6. Plate dump lever is operated to the RAISE position
7. Plate in this condition, the lamp lights up and the
8. Plate buzzer sounds to warn of the danger.
9. Connector
HD465-7R, HD605-7R 35
Steering angle sensor (for auto suspension system)
1. Body Principle of operation:

2. Tube Magnetic contactless proximity switch
3. Connector Form of output:
Turning ON when object of sensing approaches.
Function
q A round disc with teeth like a comb is installed
to the steering column. As this disc passes
through the slit in the sensor, the sensor out-
puts a pulse signal. The suspension controller
can obtain the steering speed from the number
of pulses per time.
36 HD465-7R, HD605-7R
Pressure sensor (for auto suspension system)

Suspension oil pressure sensor
1. Sensor Function
2. Tube q The suspension oil pressure switch is installed
3. Connector to the suspension cylinder. If the pressure
supplied through the pressure inlet is applied
to the diaphragm of the pressure sensor sec-
tion, the diaphragm is deflected and deformed.
A bridge consisting of strain gauges is installed
on the opposite side of the diaphragm. If the
diaphragm is deflected, the resistance of the
strain gauges changes. A constant voltage is
applied to the strain gauges and the change of
the resistance of the strain gauges is sent as a
change of voltage to the amplifier. The ampli-
fier amplifies the change of the voltage and
outputs it to the controller.
HD465-7R, HD605-7R 37
Pressure sensor (for payload meter )
1. Sensor
2. Tube
3. Connector
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
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 pressure
from going down.
The output characteristics of the sensor are as

shown in the diagram on the right.
38 HD465-7R, HD605-7R
Clinometer (for payload meter ) Lamp drive relay (for payload meter )
To carry out compensation on slopes, the clinome- The external display lamps are driven by a signal
ter measures the tilt angle of the chassis in the from the payload meter.
front-to-rear direction.
The output characteristics of the clinometer are as

shown in the diagram.
Voltage between clinometer connector pin 1 (GND)
and pin 2 (output) or voltage of output (pin (8)) of
clinometer when pin (3) of payload meter controller
connector (PH6 pin) is grounded
HD465-7R, HD605-7R 39
Blow-by pressure sensor (For VHMS) Engine oil temperature sensor

(For VHMS)
Specifications
1. Voltage of power supply: DC5V Specifications
2. Output voltage : 0.5V(engine stopped) 1. Type of sensor : Thermistor
or more 2. Range of measurement : 40 – 130 °C
3. Size: Mount (portion a) : R 1/4 : 80 – 130 °C
: Outside diameter of (guaranteed precision
seat receiving pres- ± 2 °C)
sure: 37 mm 3. Max. power consumption: 0.5 mW
: Length of cable: 4. Pressure resistance : 4.9 MPa {50 kg/cm2}
1,110 mm 5. Temperature range : --30 to 140 °C
6. Performance table
Function
The blow-by sensor converts the pressure inside Tempera- Resis- Tempera- Resis- Tempera- Resis-
ture tance ture tance ture tance
the engine crankcase into a voltage and inputs this (°C) (kz) (°C) (kz) (°C) (kz)
into the VHMS controller as the blow-by pressure.
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
Function
The engine oil temperature sensor is installed to
the engine oil filter. It inputs the change in tempera-
ture to the VHMS controller as a change in the
resistance of the thermistor.
a: Heat sensing portion of sensor, outside diame-

ter of mount R 1/4
40 HD465-7R, HD605-7R
Exhaust temperature sensor/amp Ambient temperature sensor

(For VHMS) (For VHMS)
Specifications Specifications
1. Rated voltage : DC24V 1. Electricity consumption : Max. 0.5 mW
2. Detection temperature range : 100 – 1,000 °C 2. Pressure resistance : 0.98 MPa
: 300 – 800 °C {10 kg/cm2}
(guaranteed accuracy ± 10 °C) 3. Detected temperature range (surrounding)
3. Output voltage characteristics: See table below : --30 to 120°C
4. Actuation temperature range : --40 to 110 °C 4. Retention temperature range : --30 to 140°C
5. Consumption current : Max. 30 mA 5. Performance table below
a: Heat sensing portion of sensor, outside diame-
ter of mount R 1/8 Detection
temperature --20 --10 0 10 20 50
b: Amp (°C)
c: Connector (power source end)
d: Connector (sensor end) Resistance 30.32 18.58 11.74 7.623 5.077 1.712
(kz)
Output voltage characteristics

(ambient temperature: 20 °C) ••• Reference value Function
The ambient temperature sensor inputs the ambi-
Detection ent temperature to the VHMS controller as a
temperature 50 100 400 700 800
(°C) change in the resistance of the thermistor.
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.
a: Heat sensing portion of sensor, diameter of

mount 16 x 1.5
HD465-7R, HD605-7R 41

© 2006 KOMATSU
All Rights Reserved
42 HD465-7R, HD605-7R
SEN02527-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 4
HD465-7R, HD605-7R 1
SEN02527-00 20 Standard value table
Standard value table for engine 1

Machine model HD465-7R, HD605-7R
Engine SAA6D170E-5
Classi- Standard value Permissible

Check item Measurement conditions Unit
fication for new machine value
2,270 ± 50 2,270 ± 50
(High power) (High power)
2,200 ± 50 2,200 ± 50
(Economy, (Economy,
unloaded) unloaded)
High idle 2,270 ± 50 2,270 ± 50
(Economy, (Economy,
loaded) loaded)
2,100 (+50/0) 2,100 (+50/0)
(Stationary mode (Stationary mode
• Coolant temperature: [*]) [*])
Engine speed rpm
Within operating range 945 ± 50 (Hi) 945 ± 50 (Hi)
Low idle
750 ± 50 (Lo) 750 ± 50 (Lo)
2,000 2,000
(High power) (High power)
1,900 1,900
(Economy, (Economy,
Rated speed
unloaded) unloaded)
2,000 2,000
(Economy, (Economy,
loaded) loaded)
Engine
• Engine coolant temperature: Within oper-

ating range
Intake air pressure kPa Min. 140 Min. 132
(Boost pressure) • Power train oil temperature: Within oper- {mmHg} {Min. 1,090} {Min. 990}
ating range
• When torque converter is stalling
Exhaust temperature • Whole speed range (Ambient tempera- °C Max. 680 Max. 700
ture: 20 °C)
%
At sudden Max. 25 Max. 35
• Engine coolant temper- acceleration (Bosch
(Max. 2.5) (Max. 3.5)
Exhaust gas color ature: Within operating index)
range Bosch
At high idle Max. 1.0 Max. 2.0
index
Intake valve mm 0.32 —
Valve clearance • Normal temperature
Exhaust valve mm 0.62 —
• Engine oil temperature:
Compression 40 – 60 °C Compression MPa Min. 2.94 Min. 2.1
pressure • Engine speed: pressure {kg/cm²} {Min. 30} {Min. 21}
210 – 250 rpm
• Engine coolant temperature: Within oper-
ating range
Blow-by gas pres- kPa Max. 3.43 Max. 12.94
sure • Power train oil temperature: Within oper- {mmH2O} {Max. 350} {Max. 1,320}
ating range
• When torque converter is stalling
2 HD465-7R, HD605-7R
Engine SAA6D170E-5
Classi- Standard value Permissible

fication for new machine value
• SAE0W30E0S, At torque
SAE5W40E0S, Min. 0.34 Min. 0.21
converter stall-
SAE10W30DH, {Min. 3.5} {Min. 2.1}
ing MPa
Engine oil pressure SAE15W40DH,
{kg/cm²}
SAE30DH oil Min. 0.1 Min. 0.08
• Engine oil temperature: At low idle
{Min. 1.0} {Min. 0.8}
Min. 80 °C
Engine
Oil temperature • Whole speed range (Inside of the oil pan) °C 90 – 110 MAx. 120
—
Fan belt tension • Between drive pulley and driven pulley mm (Automatic —
adjustment)
Alternator belt and —
air conditioner com- • Between drive pulley and driven pulley mm (Automatic —
pressor belt tension adjustment)
[*] 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.
HD465-7R, HD605-7R 3
Standard value table for machine 1

Standard value Permissible

for new machine value
11.5 ± 5 % 11.5 ± 5 %
F1
(10.5 ± 5 %) (10.5 ± 5 %)
16.0 ± 5 % 16.0 ± 5 %
F2
(13.0 ± 5 %) (13.0 ± 5 %)
• On flat, dry road surface
• Engine coolant tempera- 21.5 ± 5 % 21.5 ± 5 %
F3
ture: Within operating (20.0 ± 5 %) (20.0 ± 5 %)
range
Travel speed
29.5 ± 5 % 29.5 ± 5 %
F4 • Transmission oil tempera-
Max. speed at each (27.0 ± 5 %) (27.0 ± 5 %)
ture: 60 – 80 °C km/h
gear speed 39.0 ± 5 % 39.0 ± 5 %
F5 • Mode: Power mode
(Econormy mode) (36.0 ± 5 %) (36.0 ± 5 %)
• Body: When unloaded 52.5 ± 10 % 52.5 ± 10 %
F6
• Travel resistance: 3.3 % (48.0 ± 10 %) (48.0 ± 10 %)
• Standard tire 70.0 ± 10 % 70.0 ± 10 %
F7
(63.5 ± 10 %) (63.5 ± 10 %)
12.0 ± 5 % 12.0 ± 5 %
R1
(11.0 ± 5 %) (11.0 ± 5 %)
F1 o F2
F2 o F3
Shift up
F3 o F4
(Acceleration : small)
2,070 ± 50 2,070 ± 50
F4 o F5
Accelerator full
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4 1,400 ± 50 1,400 ± 50
F4 o F3
F3 o F2
F2 o F1 1,330 ± 35 1,330 ± 35
F1 o F2 2,070 ± 50 2,070 ± 50
F2 o F3
Shift up
F3 o F4
(Acceleration : large)
Automatic shift control
F4 o F5 1,950 ± 50 1,950 ± 50
Accelerator full
• Engine coolant tempera-

F5 o F6
Engine speed
ture: Within operating

Power mode
F6 o F7 range
F7 o F6 • Transmission oil tempera- rpm
F6 o F5 ture: 60 – 80 °C
Shift down
F5 o F4 • Hydraulic oil tempera- 1,400 ± 50 1,400 ± 50

F4 o F3 ture: 45 – 55 °C
F3 o F2
F2 o F1 1,330 ± 35 1,330 ± 35
F1 o F2 2,070 ± 50 2,070 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Shift up
F3 o F4
Accelerator partial
F4 o F5
1,750 ± 50 1,750 ± 50
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 35 1,200 ± 35
F5 o F4
F4 o F3
F3 o F2 1,250 ± 35 1,250 ± 35
F2 o F1 1,330 ± 35 1,330 ± 35
4 HD465-7R, HD605-7R

F1 o F2
F2 o F3
Shift up
(Acceleration : small) F3 o F4
2,070 ± 50 2,070 ± 50
F4 o F5
Accelerator full
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4 1,350 ± 35 1,350 ± 35
F4 o F3
F3 o F2
F2 o F1 1,330 ± 35 1,330 ± 35
F1 o F2 2,070 ± 50 2,070 ± 50
F2 o F3
Shift up
F3 o F4
Economy mode (Loaded)
F4 o F5 1,935 ± 50 1,935 ± 50
Accelerator full

F5 o F6
Engine speed

F6 o F7 range
F6 o F5 ture: 60 – 80 °C
Shift down
F5 o F4 • Hydraulic oil tempera- 1,350 ± 35 1,350 ± 35

F4 o F3 ture: 45 – 55 °C
F3 o F2
F2 o F1 1,330 ± 35 1,330 ± 35
F1 o F2 2,070 ± 50 2,070 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Shift up
F3 o F4
Accelerator partial
F4 o F5
1,750 ± 50 1,750 ± 50
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 35 1,200 ± 35
F5 o F4
F4 o F3
F3 o F2 1,250 ± 35 1,250 ± 35
F2 o F1 1,330 ± 35 1,330 ± 35
HD465-7R, HD605-7R 5

F1 o F2 2,000 ± 50 2,000 ± 50
Shift up F2 o F3
F3 o F4
(Acceleration : small )
F4 o F5 1,935 ± 50 1,935 ± 50
Accelerator full
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4 1,300 ± 35 1,300 ± 35
F4 o F3
F3 o F2
F2 o F1 1,250 ± 35 1,250 ± 35
F1 o F2 2,000 ± 50 2,000 ± 50
Economy mode (Unloaded)
F2 o F3
Shift up
F3 o F4
F4 o F5 • Engine coolant tempera- 1,800 ± 50 1,800 ± 50

Accelerator full
Engine speed
F5 o F6 ture: Within operating

F6 o F7 range
• Transmission oil tempera- rpm
F7 o F6 ture: 60 – 80 °C
F6 o F5
Shift down
• Hydraulic oil tempera-

F5 o F4 ture: 45 – 55 °C 1,300 ± 35 1,300 ± 35
F4 o F3
F3 o F2
F2 o F1 1,250 ± 35 1,250 ± 35
F1 o F2 2,000 ± 50 2,000 ± 50
F2 o F3
Shift up
F3 o F4
Accelerator partial
F4 o F5 1,700 – 1,850 1,700 – 1,850

F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 35 1,200 ± 35
F5 o F4
F4 o F3
F3 o F2
1,250 ± 35 1,250 ± 35
F2 o F1
6 HD465-7R, HD605-7R

F1 o F2
Coast mode (Accelerator idle)
F2 o F3
Shift up
F3 o F4
2,450 ± 50 2,450 ± 50
F4 o F5
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 35 1,200 ± 35
F5 o F4
F4 o F3
F3 o F2 1,250 ± 35 1,250 ± 35
F2 o F1 • Engine coolant tempera- 1,550 ± 50 1,550 ± 50
Engine speed
F1 o F2 ture: Within operating

F2 o F3 range
Shift up

ture: 60 – 80 °C 2,450 ± 50 2,450 ± 50
F4 o F5
Braking mode
F5 o F6 • Hydraulic oil tempera-

F6 o F7 ture: 45 – 55 °C
F7 o F6
F6 o F5
Shift down
F5 o F4
1,550 ± 50 1,550 ± 50
F4 o F3
F3 o F2
F2 o F1
F1, F2 1,300 – 1,500 1,300 – 1,500
Auto lock-up
Set
F3 – F7 1,250 – 1,500 1,250 – 1,500
F1, F2 1,100 1,100
Reset
F3 – F7 1,050 1,050
HD465-7R, HD605-7R 7

Low speed mode 1
F1 – F5, R 2,300 2,300

Set
F6, F7 2,400 2,400
Reset F1 – F7, R 2,300 2,300

Overrun prevention brake
Low speed mode 2
Set F1 – F7, R 2,450 2,450

range
Reset F1 – F7, R • Transmission oil tempera- rpm 2,300 2,300
ture: 60 – 80 °C
• Hydraulic oil tempera-
F1, F2, F7, R ture: 45 – 55 °C 2,600 2,600
High speed mode
F3 2,560 2,560
Set F4 2,530 2,530
F5 2,510 2,510
F6 2,500 2,500
Reset F1 – F7, R 2,350 2,350
Overrun Set F1 – F7, R 2,550 2,550
Engine speed
alarm Reset F1 – F7, R 2,300 2,300
Power mode • Engine coolant tempera- 1,910 ± 100 1,910 ± 100

range
Low load • Transmission oil tempera- rpm 1,860 ± 100 1,860 ± 100
Economy ture: 85 – 110 °C
mode • Hydraulic oil tempera-
High load ture: 45 – 55 °C 1,820 ± 100 1,820 ± 100
• Engine cool-
ant tempera-
ture: Within A mode 1,910 ± 100 1,910 ± 100
operating
range
At torque
• Transmis-
converter
sion oil tem-
stall B mode 1,860 ± 100 1,860 ± 100
perature: 85
At inspection using – 110 °C
engine mode fixing • Hydraulic oil
temperature: rpm
function set of machine
monitor 45 – 55 °C
a For details, C mode 1,820 ± 100 1,820 ± 100
see Testing
and adjust-
ing, "Special
functions of
machine D mode 1,820 ± 100 1,820 ± 100
monitor
(EMMS)".
8 HD465-7R, HD605-7R

Starting to N 29.4 (+9.8/-4.9) 29.4 (+9.8/-4.9)
Operating depress {kg} {3.0 (+1.0/-0.5)} {3.0 (+1.0/-0.5)}
effort • Point at 150 N 58.8 (+4.9/-9.8) 58.8 (+4.9/-9.8)
Operating force and stroke
Full
Accelerator pedal mm from ful- {kg} {6.0 (+0.5/-1.0)} {6.0 (+0.5/-1.0)}
crum of pedal Starting to
Stroke depress mm 45 ± 5 45 ± 5
o Full
RoN
Operating NoD N
Max. 29.4 {3.0} Max. 29.4 {3.0}
effort Do6 {kg}
• At center of 6o5
Gear shift lever
knob 5o4
4o3
Stroke 3o2 mm 24.5 ± 1 24.5 ± 2
2o1
Inlet oil 0.74 ± 0.05 0.74 ± 0.05
pressure {7.5 ± 0.5} {7.5 ± 0.5}
Oil pressure
• Oil temperature: 80 °C
Outlet oil MPa 0.59 ± 0.05 0.59 ± 0.05
Torque convertor • Engine speed: 2,000 rpm {kg/cm²}
pressure {6.0 ± 0.5} {6.0 ± 0.5}
(Rated speed)
Lock-up oil 1.67 ± 0.2 1.67 ± 0.2
pressure {17.0 ± 2.0} {17.0 ± 2.0}
3.68 ± 0.2 3.68 ± 0.2
oil pressure
Main relief
F1 – F3, R
{37.5 ± 2.0} {37.5 ± 2.0}
2.28 ± 0.2 2.28 ± 0.2
F4 – F7
{23.2 ± 2.0} {23.2 ± 2.0}
1.91 ± 0.2 1.91 ± 0.2
Lo cluch
{19.5 ± 2.0} {19.5 ± 2.0}
Control valve set pressure
1.72 ± 0.2 1.72 ± 0.2

Hi cluch • Oil temperature: 80 °C
Transmission
{17.5 ± 2.0} {17.5 ± 2.0}

Oil pressure
• Engine speed: 2,000 rpm

(Rated speed) MPa 1.67 ± 0.2 1.67 ± 0.2
4th cluch
{kg/cm²} {17.0 ± 2.0} {17.0 ± 2.0}
1.86 ± 0.2 1.86 ± 0.2
3rd cluch
{19.0 ± 2.0} {19.0 ± 2.0}
2nd cluch 3.28 ± 0.2 3.28 ± 0.2
1st cluch {33.5 ± 2.0} {33.5 ± 2.0}
3.19 ± 0.25 3.19 ± 0.25
R cluch
{32.5 ± 2.5} {32.5 ± 2.5}
Lubricating valve set 0.15 ± 0.05 0.15 ± 0.05
pressure • Oil temperature: 80 °C {1.5 ± 0.5} {1.5 ± 0.5}
Standard
24.00-35-
tire 0.47 ± 0.01 0.47 ± 0.01
Air pressure
36PR (Front,
(HD465- {4.75 ± 0.1} {4.75 ± 0.1}
rear wheel) MPa
Tire 7R) • Machine unloaded {kg/cm²}
Standard 24.00R35
0.69 ± 0.01 0.69 ± 0.01
(HD605- (Front, rear
{7.0 ± 0.1} {7.0 ± 0.1}
7R) wheel)
HD465-7R, HD605-7R 9

Stop slope angle
• With 55 t payload
(HD465-7R)
• With 63 t payload °
Braking capacity 11.5 11.5
(HD605-7R) (degree)
Parking brake
• Machine can be stopped

at standard value
• F2
Engine
speed
Starting test • Torque converter stall rpm Min. 1,670 Min. 1,670
• Machine can be stopped
at standard value
MPa
Releasing pressure (See "Brake") (See "Brake")
—
{kg/cm²}
• On flat dry road surface
Front • When unloaded 249 ± 10 249 ± 20
• Dimension see Fig. 1 in
Dimension
Installed "A"
mm
length • On flat dry road surface
Suspension cylinder
Rear • When unloaded 204 ± 10 204 ± 20

• Dimension see Fig. 1 in
"B"
3.88 ± 0.40 3.88 ± 0.40
Pressure Front
{39.6 ± 4.0} {39.6 ± 4.0}
(HD465-
7R) 2.31 ± 0.24 2.31 ± 0.24
Rear
Pressure
• On flat dry road surface MPa {23.6 ± 2.4} {23.6 ± 2.4}

• When unloaded {kg/cm²} 4.23 ± 0.42 4.23 ± 0.42
Pressure Front
{43.2 ± 4.3} {43.2 ± 4.3}
(HD605-
7R) 2.62 ± 0.26 2.62 ± 0.26
Rear
{26.8 ± 2.7} {26.8 ± 2.7}
Stationary steering effort • On flat dry road surface
Operating
(If stationary steering

N 14.7 – 29.4 14.7 – 29.4
is impossible, measure • Steering wheel speed: 10
force
rpm {kg} {1.5 – 3.0} {1.5 – 3.0}

steering effort at low
speed) • Engine run
Number of Dimension
• Engine stop
Play • Dimension on periphery mm Max. 135 Max. 135
of grip
Steering wheel
Num-
rotation
Rotation range • Lock o Lock ber of 3.5 ± 0.3 3.5 ± 0.3

rotation
Engine
speed: At Max. 5.2 Max. 5.2
• Lock o Lock 750 rpm
• Steering
Time
Turning time sec.

wheel speed: Engine
speed: At
60 rpm Max. 3.6 Max. 3.6
1,500,
2,000 rpm
10 HD465-7R, HD605-7R

At High 22.5 ± 0.98 22.5 ± 0.98
Dimension Operating Angle Operating Dimension Operating Oil pressure
Steering
• Oil tempera- idle {230 ± 10} {230 ± 10}

MPa
valve
Relief oil pressure ture: {kg/cm²} 18.6 ± 0.98 18.6 ± 0.98

45 – 55 °C At Low idle
{190 ± 10} {190 ± 10}
N 235 ± 29.4 235 ± 29.4

effort
Operating effort
{kg} {24 ± 3.0} {24 ± 3.0}
Brake pedal
• Measuring point: Point at

150 mm from fulcrum of
pedal
Stroke mm 40 ± 5 40 ± 10
control lever
N 5.88 – 9.8 3.0 – 14.7

effort
Operating effort • Measuring point: Point at

Retarder
10 mm from lever end {kg} {0.6 – 1.0} {0.3 – 1.5}

(Point at 167 mm from
fulcrum of lever) °
Stroke (Operating range) 0 – 78 (+0/-2) 0 – 78 (+0/-4)
(degree)
N 294 ± 29.4 294 ± 29.4

effort
Operating effort
{kg} {30 ± 3.0} {30 ± 3.0}
brake pedal
Emergency
• Measuring point: Point at

150 mm from fulcrum of
pedal
Stroke mm 46 ± 5 46 ± 10
For front 10.7 ± 0.34 10.7 ± 0.34

Gas pressure
service brake {109 ± 3.5} {109 ± 3.5}

Accumulator
Nitrogen • Gas temperature

For rear MPa 6.2 ± 0.20 6.2 ± 0.20
gas (ambient temperature):
service brake {kg/cm²} {63 ± 2.0} {63 ± 2.0}
pressure 20 ± 5 °C
For parking 6.2 ± 0.20 6.2 ± 0.20
brake {63 ± 2.0} {63 ± 2.0}
14.2 (+0.49/0) 14.2 (+0.49/0)
charge valve
Accumulator
Oil pressure
Cut-in pressure
• Oil temperature: {145 (+5/0)} {145 (+5/0)}
MPa
45 – 55 °C
{kg/cm²} 20.6 (+0.98/0) 20.6 (+0.98/0)
Cut-out pressure • High idle
{210 (+10/0)} {210 (+10/0)}
HD465-7R, HD605-7R 11

• Dry flat road When

Max. 17.0 Max. 17.0
• At max. unloaded
brake opera-
HD465-7R
Stopping distance with
tion pressure
Front: With 55 t
service brake
Max. 29.0 Max. 29.0

17.6 MPa payload
{180 kg/cm²}
Rear:
9.8 MPa When
Max. 22.3 Max. 22.3
{100 kg/cm²} unloaded
HD605-7R • From check
of sign to stop
• Initial speed: With 63 t
Max. 29.0 Max. 29.0
32 km/h payload
Distance
m
• Dry flat road
When
Braking distance with service brake
• At max. Max. 11.2 Max. 11.2

unloaded
brake opera-
HD465-7R tion pressure
Front: With 55 t
17.6 MPa Max. 23.6 Max. 23.6
payload
{180 kg/cm²}
Rear:
9.8 MPa When
{100 kg/cm²} Max. 16.5 Max. 16.5
unloaded
• From start of
HD605-7R braking to
stop With 63 t
• Initial speed: Max. 23.6 Max. 23.6
payload
32 km/h
Brake
17.6 ± 1.2 17.6 ± 1.2

Front
{180 ± 12} {180 ± 12}
Operating Rear (Ser- MPa 9.8 ± 0.69 9.8 ± 0.69
Oil pressure
pressure vice brake) • At full stroke {kg/cm²} {100 ± 7} {100 ± 7}

Rear 8.7 ± 0.64 8.7 ± 0.64
(Retarder) {88.5 ± 6.5} {88.5 ± 6.5}
9.85 9.85
Parking brake releasing MPa
• Stop engine (+0.98/-0.49) (+0.98/-0.49)
pressure {kg/cm²}
{100.4 (+10/-5)} {100.4 (+10/-5)}
• Dry flat road
• From start of braking to
stop
Distance
Stopping distance
when emergency • Initial speed: 32 km/h m Max. 52.1 Max. 52.1
brake is applied • With 55 t payload
(HD465-7R)
• With 63 t payload
(HD605-7R)
Servise brake • When unloaded Max. 1,870 Max. 1,870
Retarder • Concrete road
At brake • At max. brake operation Max. 1,400 Max. 1,400
Engine
brake
speed
starting pressure rpm

test • Gear speed: F2
Parking brake • Machine must not move Max. 1,670 Max. 1,670
off at standard speed stall
Thickness
Front brake pad mm 19.5 3.0

Pad and disc wear
Rear brake disk — Must be in wear gauge range
12 HD465-7R, HD605-7R

Max. 29.4 Max. 29.4
Hold o Raise
{Max. 3.0} {Max. 3.0}
Lever must Lever must
Raise o Hold reset itself reset itself
automatically automatically
Operating effort
Operating effort
Max. 29.4 Max. 29.4

Hold o Float • Measuring point: Center
of grip N {Max. 3.0} {Max. 3.0}
(Point at 80 mm from ful- {kg} Max. 29.4 Max. 29.4
Dump lever
Float o Hold
crum) {Max. 3.0} {Max. 3.0}
Lever must Lever must
Lower o
reset itself reset itself
Float
automatically automatically
Float o Max. 29.4 Max. 29.4
Lower {Max. 3.0} {Max. 3.0}
Raise o Hold 23.5 ± 1 23.5 ± 1
Operating
Operating
Hold o Float
angle
angle
° 10.5 ± 1 10.5 ± 1
—
(degree)
Lower o
13.0 ± 1 13.0 ± 1
Float
Relief 20.1 – 21.1 19.6 – 22.6
Oil pressure
Hoist valve At Hi idle

pressure • Oil {205 – 215} {200 – 230}
MPa
Relief pres- temperature: {kg/cm²}
45 – 55 °C 3.4 ± 0.49 3.4 ± 0.49
Dump EPC valve sure (root At Hi idle
{35 ± 5} {35 ± 5}
pressure)
Lifting speed 11.5 ± 1.5 11.5 ± 1.5
• Engine speed: 2,000 rpm
Time
• Oil temperature: sec.

Lowering speed 50 – 70 °C 11.5 ± 1.5 11.5 ± 1.5
Body • Dump lever: "Float"
Dimension
• From 100 mm extension

of 2nd cylinder
Hydraulic drift mm Max. 85 Max. 170
• Measuring time:
5 minutes
Fig. 1: Installed length (A) of front suspension cylin-

der rod and installed length (B) of rear suspension
cylinder rod
HD465-7R, HD605-7R 13

© 2007 KOMATSU
All Rights Reserved
14 HD465-7R, HD605-7R
SEN02528-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 6
Testing air supply pressure (boost pressure) .................................................................................................. 7
Testing exhaust temperature........................................................................................................................... 8
Testing exhaust gas color ............................................................................................................................. 10
Adjustment of valve clearance ...................................................................................................................... 12
Testing of compression pressure .................................................................................................................. 14
Testing blow-by pressure .............................................................................................................................. 17
Testing engine oil pressure ........................................................................................................................... 18
Handling of fuel system devices ................................................................................................................... 19
Releasing residual pressure from fuel system .............................................................................................. 19
Testing of fuel pressure................................................................................................................................. 20
Cylinder cut-out mode operation................................................................................................................... 21
No-injection cranking .................................................................................................................................... 21
Testing of fuel return rate and fuel leakage................................................................................................... 22
Bleeding air from fuel circuit.......................................................................................................................... 24
HD465-7R, HD605-7R 1
SEN02528-00 30 Testing and adjusting
Testing the fuel circuit for leakage................................................................................................................. 25

Replacing and adjusting of fan belt ............................................................................................................... 26
Replacing and adjusting of alternator and air conditioner compressor belt .................................................. 27
2 HD465-7R, HD605-7R
Tools for testing, adjusting, and troubleshooting 1

Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
-101 – 200 kPa
799-201-2202 Boost gauge kit 1
Testing intake air pressure {-760 – 1,500 mmHg}
A
(boost pressure) I-shaped coupler type
799-401-2220 Hose 1
(when necessary)
799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
Testing exhaust
B 6215-11-8171 Sensor 1 Wire length: 490 mm
temperature
799-201-1110 Wiring harness 1
1 799-201-9001 Handy smoke checker 1
Testing exhaust color C Commercially Bosch index: 0 – 9
2 Smoke meter 1
available
Commercially Intake: 0.32 mm
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.62 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm²}
795-611-1220 Adapter 1
Testing compression 2
E 6261-71-6150 Gasket 1
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Testing blow-by pressure F 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm²}
Pressure gauge:
Testing engine oil 790-261-1204 Digital hydraulic tester 1
G 58.8 MPa {600 kg/cm²}
pressure
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0.98 MPa {10 kg/cm²}
799-101-5230 Nipple 1 14 × 1.5 mm
3
6215-81-7920 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm²}
Pressure gauge:
Testing fuel pressure H 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm²}
2 795-471-1450 Adapter 1
Pressure gauge:
3 799-401-2320 Gauge 1
1 MPa {10 kg/cm²}
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
Measurement of leakage available
through pressure limiter Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
and return rate from available
injector
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
HD465-7R, HD605-7R 3
Sym-
Q'ty
bol
Pressure gauge:
Oil pressure gauge KIT
799-101-5002 1 2.5, 6, 40, 60 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm²}
Testing power train oil Oil pressure gauge KIT Pressure gauge:
pressure 790-261-1204 1
(Digital) 60 MPa {600 kg/cm²}
799-101-5220 Nipple 1
2 M10 × 1.25
07002-11023 O-ring 1
Pressure gauge:
799-101-5002 1 2.5, 6, 40, 60 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm²}
Testing brake oil pressure
Oil pressure gauge KIT Pressure gauge:
799-261-1204 1
3 566-35-43561 Nipple 1 18 × 1.5 (Female: PT 1/8)
K Pressure gauge:
799-101-5002 1 2.5, 6, 40, 60 MPa
Testing steering/hoist oil (Analog)
1 {25, 60, 400, 600 kg/cm²}
pressure circuit
790-261-1204 1
Pressure gauge:
799-101-5002 1 2.5, 6, 40, 60 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm²}
Testing dump EPC oil 790-261-1204 1
pressure circuit
4 799-101-5230 Nipple 1 14 × 1.5
799-401-3100 Adapter 1 Face seal type (# 02)

5 (Female: PT 1/8)
02896-11008 O-ring 1
Measurement of wear of
— 566-98-41410 Gauge 1 Tool mounted on machine
front brake pad
1 792-610-1000 Suspension tool 1
2 792-610-1130 Pump assembly 1
3 792-610-1110 Hose 1 L2 – L6
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
L 7 792-610-1250 Valve assembly 1
adjustment
8 792-610-1260 Nipple 1 L7 – L13
9 792-610-1480 Stem 1 Charging tool assembly KIT
10 792-610-1640 Joint 1 part No. 792-610-1200
11 792-610-1400 Regulator assembly 1
12 792-610-1430 Gauge 1 25 MPa {250 kg/cm²}
13 792-610-1440 Gauge 1 10 MPa {100 kg/cm²}
At raise of emergency
M 792T-491-1110 Plug 1 Refer to the sketch
dump body
1 799-608-3211 Discket
Initial set up of VHMS con- 2 799-608-3220 Harness
N
troller and, at repair set up Commercially Lap top type personal OS: Windows 98/2000/Me/XP
3
available computer Terminal "RS232C" is with it
4 HD465-7R, HD605-7R
Sym-
Q'ty
bol
1 792-610-1700 Gas charge tool 1
792-610-1310 Nipple (For Russia) GOST
792-610-1320 Nipple (For USA) CGA No. 351
ASA
792-610-1330 Nipple (For USA)
Gas pressure check and B-571-1965
P
filling of the accumulator 2 1 DIN 477-1963
NEN 3268-1966
792-610-1350 Nipple (For Germany)
SIS-SMS
2235/2238
BS341
792-610-1360 Nipple (For UK)
Part 1-1962
Testing coolant tempera-
– 799-101-1502 Digital temperature gauge 1 -99. 9 – 1,299 °C
ture and oil temperature
Testing lever and padal – 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
operating effort and pedal
effort – 79A-264-0091 Push-pull scale 1 0 – 500 N {0 – 50 kg}
Testing stroke and hydrau- Commercially

– Scale 1
lic drift available
Testing work equipment Commercially
– Stopwatch 1
speed available
Testing voltage and resis- Commercially
– Multimeter 1
tance available
Sketch of special tool

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these draw-
ings.
M Plug
HD465-7R, HD605-7R 5
Testing engine speed 1

k Stop the machine on flat ground, turn the
parking brake switch PARKING, and set
chocks to the tires.
a Test the engine speed under the following con-
dition.
q Engine coolant temperature:
Within operating range
q Torque converter oil temperature:
q Hydraulic oil temperature: 45 – 55 °C
1. Preparation work
Turn the starting switch ON and set the
machine monitor (EMMS) in the "Monitoring
function of service mode" to prepare for testing
of the engine speed.
q Monitoring system: ENGINE
q Monitoring code: 01002 (ENG SPEED)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
2. Testing low idle speed

1) Set the gear shift lever to "N" and dump
lever to HOLD.
2) Start the engine and measure the engine
speed without depressing the accelerator
pedal.
3. Testing high idle speed

1) Set the shift lever to "N" and dump lever to
HOLD.
2) Start the engine and set the accelerator
pedal in the high idle position and mea-
sure the engine speed.
4. Testing torque converter stall speed

See "Testing of torque converter stall speed"
(in "Testing and adjusting (Part 2)".
6 HD465-7R, HD605-7R
Testing air supply pressure

(boost pressure) 1
a Testing instrument
Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Stop the machine on the level ground, turn

the parking brake switch PARKING, and set
k Be careful not to touch any hot parts when
installing or removing the testing tools. 3. Install nipple [1] and hose [2] and connect
a Test the air supply pressure (boost pressure) gauge (A) of the boost gauge kit to the mea-
under the following conditions. suring hole.
q Coolant temperature:
(Testing with monitor panel)

1. Change the machine monitor to "Service
mode" and display the following 2 items simul-
taneously with the "Monitoring function".
q Monitoring system: 2 ITEMS
q Monitoring code: 36500 (CHG PRESS-A)
4. Run the engine at mid-range speed or above
to bleed the oil from the hose.
a Insert the hose connector into the pres-
sure garge about half way and repeat the
action to open the self-seal in the hose to
bleed the oil.
a If Pm kit is available, the air bleed coupling
(790-261-1130) inside the kit can be used.
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
5. Run the engine at high idle to stall the torque

converter, and measure the air supply pres-
sure (boost pressure).
a For details of the procedure for stalling the
a For the method of testing, see "Method torque converter, see "Testing torque con-
with testing instruments". verter stall speed".
(Method with testing instruments) 6. After completing the testing, rermove the test-
1. Open the engine hood. ing equipment and set to the original condition.
2. Remove air supply pressure measuring hole

plug (1).
HD465-7R, HD605-7R 7
Testing exhaust temperature 1

799-101-1502 Digital temperature gauge
B 6215-11-8171 Sensor
799-201-1110 Wiring harness

k Wait for the temperature of the exhaust
manifold to go down before installing or
removing the testing equipment.
a Test the exhaust temperature under the follow-
ing conditions.
(Method with testing instruments)

1. Remove the cover in the right front fender.
2. Remove exhaust temperature measuring hole
plug (1) from the exhaust manifold. 4. Method of periodic testing for preventive main-
a Test at each of the front and rear holes. tenance service.
a To prevent the torque converter from over-
heating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the
exhaust temperature, then stall only the
torque converter and test the temperature.
1) Turn the power mode switch to the HIGH
POWER position.
2) Start the engine and raise the temperature
of the coolant to the operating range.
3) Depress the parking brake pedal, turn the
parking brake switch OFF, then set the
gearshift lever to the D position.
k If the torque converter is stalled
while the gearshift indicator is indi-
3. Install sensor [1], then connect to digital tem- cating "F1", the inside of the trans-
perature gauge (B). mission may be broken.
a Clamp the wiring harness of the sensor [1] Accordingly, when stalling the
at a suitable place to prevent it from touch- torque converter, seat the body
ing any hot part. securely and check that the body
pilot lamp is turned OFF, and then
set the gearshift lever in the D
position and check that the gear-
shift indicator is indicating "F2".
4) Depress the accelerator pedal gradually,
run the engine at high idle and stall the
torque converter. At the same time, oper-
ate the dump lever to the LOWER position
and relieve the oil pressure (full stall).
a Continue the above operation until
the exhaust temperature is stabilized.
8 HD465-7R, HD605-7R
k There is danger of damage to the (Method using monitoring)

internal parts of the transmission, a This method applies only to the VHMS specifi-
so never operate the gearshift cation.
lever to any position other than the 1. Switch the machine monitor display to "Service
D position during the stall opera- mode" and use the "Monitoring function" to dis-
tion. play the following two items at the same time.
5) When the temperature stabilizes at near q Monitoring system: 2 ITEMS
the target temperature, return the dump q Monitoring code: 01002 (ENG SPEED)
lever to FLOAT and test the temperature q Monitoring code: 42612 (EXHAUST TMP F)
with only the torque converter stalled. a For the operating method, see "Special
a The exhaust temperature will start to functions of machine monitor (EMMS)".
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
go down but rises, make the set tem-
perature at full stall higher.
a After completing the testing, lower the
engine speed to low idle, then return
the gearshift lever to the N position.
5. When testing the maximum value for the ex-

haust temperature during troubleshooting, do
as follows.
Carry out actual work and record the maximum
exhaust temperature during operation. q Monitoring system: 2 ITEMS
a Use the PEAK mode of the digital temper- q Monitoring code: 01002 (ENG SPEED)
ature gauge. (Set the temperature gauge q Monitoring code: 42611 (EXHAUST TMP R)
to the PEAK mode. The maximum tem- a For the operating method, see "Special
perature automatically recorded.) functions of machine monitor (EMMS)".
a The exhaust temperature largely depends
on the ambient temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q Corrected value [°C] = Tested value +
2 × (20 – ambient temperature)
6. After completing the testing, remove the test-

ing equipment and set to the original condition.
a For other testing methods, see "Methods

with testing tools".
HD465-7R, HD605-7R 9
Testing exhaust gas color 1 2. Testing with smoke meter C2

1) Raise the body and fix it with the lock pin
a Testing instrument securely.
2) Insert probe [1] of smoke meter C2 in the
outlet of exhaust pipe (1) and fix it to the
1 799-201-9001 Handy smoke checker exhaust pipe with a clip.
C Commercially
2 Smoke meter
available

k When installing and removing the testing
instrument, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
1. Testing with handy smoke checker C1 3) Connect the probe hose, plug of the accel-
1) Raise the body and fix it with the lock pin erator switch, and air hose to smoke
securely. meter C2.
2) Attach a sheet of filter paper to handy a Restrict the supplied air pressure
smoke checker C1. below 1.5 MPa {15 kg/cm²}.
3) Insert the exhaust gas intake pipe in 4) Connect the power cable to the power
exhaust pipe (1). source.
4) Start the engine and raise the temperature a Before connecting the cable, check
of the engine to the operating range. that the power switch of the smoke
5) As increasing the engine speed rapidly or meter is turned off.
running it at high idle, operate the handle 5) Loosen the cap nut of the suction pump
of handy smoke checker C1 so that the fil- and fit the filter paper.
ter paper absorbs the exhaust gas. a Fit the filter paper securely so that the
exhaust gas does not leak.
6) Turn on the power switch of smoke meter
C2.
6) Remove the filter paper and compare it with

the attached scale to make a judgment.
7) When the testing is completed, remove
the instruments and set to the original
condition.
10 HD465-7R, HD605-7R
7) Start the engine and raise the coolant tem-

perature of the engine to the operating
range.
8) As increasing the engine speed rapidly or
running it at high idle, depress the acceler-
ator pedal of smoke meter C2 and collect
the exhaust gas with the filter paper.
9) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
10) When the testing is completed, remove
the instruments and set to the original
condition.
HD465-7R, HD605-7R 11
Adjustment of valve clearance 1

Commercially
D Thickness gauge
available

1. Open the engine hood.

5. Rotate the crankshaft forward to set notch (a)
2. Remove coolant reservoir tank (1), covers (2) of the supply pump drive gear to the center of
and (3) and bracket (4) and then remove 6 cyl- the inspection hole on the left side of the timing
inder head covers (5). gear case.
a The left side of the following figure shows
the compression top dead center of the
No. 1 cylinder and the right side shows
that of the No. 6 cylinder.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arms of
the No. 1 cylinder can be moved by hand
to the extent of the valve clearance. If the
rocker arm cannot be moved, the No. 1
cylinder is not at the compression top
dead center. In this case, rotate the
crankshaft one more turn.
3. Remove inspection hole plug (6) from the left

side of the timing gear case.
6. While the No. 1 cylinder is at the compression

top dead center, adjust the valve clearances
marked with q in the valve arrangement draw-
ing.
4. Pull out pin (8) from barring device (7) at the
a Loosen locknut (11) of adjustment screw
rear of the left side of the engine and rotate the
(10) and insert thickness gauge D
engine while pressing shaft (9).
between crosshead (12) and rocker arm
a The upper part of the figure is the rear part
(13), and set adjustment screw (10) to a
of the engine.
degree that you can move the thickness
gauge with only a slight drag.
a Standard valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
12 HD465-7R, HD605-7R
7. While fixing adjustment screw (10), tighten

locknut (11).
3 Locknut:
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.
8. Rotate the crankshaft forward by 1 turn and

adjust the valve clearance marked with Q in
the valve arrangement drawing.
a Adjust the valve clearance according to
the above procedure.
9. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
[No. 1, 3, 4, 5 and 6 cylinders]
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[No. 2 cylinder]
58.8 – 73.5 Nm {6 – 7.5 kgm}
HD465-7R, HD605-7R 13
Testing of compression pressure1 6. Remove holder (8), adapter and injector (9).
1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
E 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover

chocks to the tires. a Insert the pin (indicated with the arrow) at
k When testing the compression pressure, the end of tool E3 into the hole (a) of
take care not to burn yourself on the ex- adapter (10), and move the weight of tool
haust manifold, muffler, etc. or get caught E3 up and down to pull out the injector.
in a rotating part.
a Test the compression pressure after the engine
is warmed up (Engine oil temperature: 40 – 60
°C).
1. Open the engine hood.
2. Remove coolant reserve tank (1), covers (2)

and (3) and bracket (4).
3. Remove the cylinder head cover (5) of the cyl-

inder to test the compression pressure.
4. Adjust the valve clearance of the cylinder to be

checked. For details, see "Adjustment of valve
clearance".
5. Disconnect fuel high-pressure tube (6) and

injector wiring harness (7).
a Remove the terminal of the injector wiring
harness on the injector side and the
mounting bolt on the rocker housing side
and remove the injector wiring harness
from the injector.
a Loosen the 2 terminal nuts alternately.
14 HD465-7R, HD605-7R
7. Install adapter E2 to the mounting hole of the

injector and connect compression gauge E1.
a Fit the gasket to the injector end without
fail.
a Fix the adapter with the holder and adapt-
er for the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
3) Install holder (8) and tighten bolt (14) with

washer (15) temporarily.
2 Spherical part of washer: Engine oil
4) Install fuel high-pressure tube (6) and
tighten the sleeve nut temporarily.
5) Tighten bolt (14) permanently.
3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
6) Tighten sleeve nut (6) permanently.
3 Sleeve nut:
39.2 – 44.1 Nm {4 – 4.5 kgm}
8. Set the engine in the no-injection cranking

mode.
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
a For the setting method, see "Special func-
tions of machine monitor (EMMS).
9. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized. a Install the injector wiring harness accord-
ing to the following procedure.
10. After finishing testing, remove the testing 1) Install injector wiring harness (7) from
instruments and return the removed parts. inside of the rocker arm housing and fix
a Install the injector and fuel high-pressure the connector end with plate (16).
tube according to the following procedure.
1) Fit gasket (11) and O-rings (12) and (13)
to injector (9).
a Take care not to fit O-ring (12) to
groove (b).
2 O-ring: Engine oil
2) Push injector (9) into the cylinder head
with adapter (10) being set to injector.
HD465-7R, HD605-7R 15
2)Set spacer (17) and fix it with bolt (18).

3)Tighten nuts (19) on the injector side alter-
nately.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Tighten the cylinder head cover mounting

bolts to the following torque.
3 Cylinder head cover mounting bolt:
[No. 1, 3, 4, 5 and 6 cylinders]
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[No. 2 cylinder]
58.8 – 73.5 Nm {6 – 7.5 kgm}
16 HD465-7R, HD605-7R
Testing blow-by pressure 1 a After completing the testing, run the en-
gine at low idle, then return the gearshift
a Testing instrument lever to the N position.

F 799-201-1504 Blow-by checker

(Method using testing equipment)

1. Install nozzle [1] and hose [2] of blow-by
checker F to blow-by hose (1) and connect
them to gauge [3].

(Method using monitoring function)

a This method applies only to the VHMS specifi-
cation.
1. Switch the machine monitor display to "Service
mode 1" and use the "Monitoring function" to
display the following two items at the same
time.
q Monitoring code: 42801 (BLOWBY PRESS)
2. Start the engine and raise the temperature of
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.
k If the gearshift lever is set to any posi-
tion other than the D position, the
machine may move off even if the
brake is being depressed, so always
test at the D position.
4. Depress the accelerator pedal gradually, run

the engine at high idle and stall the torque con-
verter, and test the blow-by pressure.
k If the torque converter is stalled while a For details of the method of testing, see
the gearshift indicator is indicating "Method using testing equipment".
"F1", the inside of the transmission
may be broken. Accordingly, when
stalling the torque converter, seat the
body securely and check that the body
pilot lamp is turned OFF, and then set
the gearshift lever in the D position and
check that the gearshift indicator is
indicating "F2".
HD465-7R, HD605-7R 17
Testing engine oil pressure 1 (Method with testing instruments)

1. Remove engine oil pressure pickup plug (1)
a Testing instrument from the left side of the cylinder block.

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Hydraulic tester
G 2 790-401-2320
(0.98 MPa {10 kg/cm²})
799-101-5230 Nipple
3
6215-81-9720 O-ring

a Test the engine oil pressure under the follow-
ing conditions. 2. Fit nipple [1] of hydraulic tester G1, then con-
q Engine oil temperature: Min. 80 °C nect to hydraulic tester G2.
(Testing with monitor panel)

a Display the following 2 items with the "Monitor-
ing function of Service mode 1" of machine
monitor (EMMS).
q Monitoring code:
37200 (ENGIN OIL PRESS)
3. Run the engine and test the engine oil pres-
sure at low idle and high idle.

18 HD465-7R, HD605-7R
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low pressure cir-
The common rail fuel injection system (CRI) cuit and high pressure circuit of the fuel system
consists of more precise parts than the con- while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause Feed pump – Fuel filter – Fuel supply
trouble. When testing and maintaining the fuel pump
system, take care more than the past. If dust, High pressure circuit:
etc, sticks to any part, wash that part thor- Fuel supply pump – Common rail –
oughly with clean fuel. Fuel injector
a Precaution for replacing fuel filter cartridge. a The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level
tridge. Since the common rail fuel injection automatically 30 seconds after the engine is
system (CRI) consists of more precise parts stopped.
than the conventional fuel injection pump and a Before the fuel circuit is tested and its parts are
nozzle, it employs a high-efficiency special fil- removed, the residual pressure in the fuel cir-
ter to prevent foreign matter from entering it. If cuit must be released completely. Accordingly
a filter other than the genuine one is used, the observe the following.
fuel system may have trouble. Accordingly, k When testing the fuel line or removing or
never use such a filter. installing equipment of fuel system, wait for
at least 30 seconds after the engine is
stopped to release the remaining pressure
in the fuel circuit before starting operation.
(There is still pressure remaining in the cir-
cuit, so do not start operations immediately
after the engine is stopped.)
HD465-7R, HD605-7R 19
Testing of fuel pressure 1 5. Run the engine and test the fuel pressure at
high idle.
a Testing instrument a If the fuel pressure is in the following stan-
dard range, it is normal.
Symbol Part number Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester Min. 0.15 MPa
H High idle
2 795-471-1450 Adapter {1.5 kg/cm²}
3 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the fuel pressure is very high in the
high-pressure circuit from the supply pump
through the common rail to the injector, it
cannot be measured.
6. After finishing testing, remove the testing in-
1. Remove the cover in the left front fender.
struments and return the removed parts.
2. Remove fuel pressure pickup plug (1) from the
top of the fuel filter.
3. Install adapter H2 and nipple [1] of hydraulic

tester H1 and connect them to gauge H3.
4. Install fuel air bleeder piping (1) again.
20 HD465-7R, HD605-7R
Cylinder cut-out mode operation 1 No-injection cranking 1

a Cylinder cut-out mode operation means to run a No-injection cranking means to crank the en-
the engine with the fuel injectors of 1 or more gine with the starting motor while all the injec-
cylinders disabled electrically to reduce the tions are stopped electrically. The purpose
number of effective cylinders. The purposes and effect of this operation are as follows.
and effects of this operation are as follows. q Before the engine is started after it or the ma-
chine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
a For the setting method, see "Special functions
2. When a cylinder is selected for the reduced of machine monitor (EMMS)".
cylinder mode operation, if the engine speed
and output do not change from the all-cylinder
operation, that cylinder has 1 or more defects.
The possible defects are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring or cylinder lin-
er
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a For the setting method, see "Special func-
tions of machine monitor (EMMS)".
HD465-7R, HD605-7R 21
Testing of fuel return rate and fuel

leakage 1
Symbol Part number Part name
1 6167-11-6640 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder 5) Install joint J2 to common rail (1) using the
available
removed joint bolt.
Commercially
6
available
Stopwatch a Be sure to fit the gaskets to both ends
of the joint.
a Prepare an oil pan of about 20 l to receive the 6) Connect test hose J3 to the end of joint
fuel flowing out during the measurement. J2.
a Bind the connecting part of the test
hose with a wire etc. to prevent it from
1. Preparation work
coming off.
1) Open the engine hood. a The above is the preparation work for
2) Remove all the covers around the inspec- measurement of the leakage from the
tion points. pressure limiter.
3) Remove tube (2) between common rail (1)
and block (3).
4) Install spacer J1 to block (3) side and

tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.
22 HD465-7R, HD605-7R
2. Testing of leakage from pressure limiter 4) After the engine speed is stabilized, mea-
1) Lay test hose J3 so that it will not slacken sure the return rate in 1 minute with mea-
and put its end in the oil pan. suring cylinder J5.
2) Referring to "Testing of engine speed", a You may measure for 20 seconds and
prepare for testing of the engine speed. judge by multiplying the result by 3.
3) Start the engine and keep its speed to a If the supply pump is not supplying
rated speed. fuel, the engine speed may not rise.
In this case, record the engine speed,
4) After the engine speed is stabilized, mea-
too, during the measurement.
sure the leakage in 1 minute with measur-
a If the return rate (spill) from the injec-
ing cylinder J5.
tor is in the following standard range,
a You may measure for 20 seconds and
it is normal.
judge by multiplying the result by 3.
a If the leakage from the pressure lim- Rated output speed Limit of return rate
iter is in the following standard range, (rpm) (spill) (cc/min)
it is normal. 1,600 960
Measurement Leakage 1,700 1,020
condition (cc/min) 1,800 1,080
Rated speed Max. 10 1,900 1,140
2,000 1,200
5) After finishing measurement, stop the en-

gine.
5) After finishing measurement, stop the en-
gine.
3. Measurement of return rate from injector
1) Disconnect spill outlet hose (4), connect
4. Work after finishing measurement
test hose J4 and put its end in the oil pan.
After finishing all measurement, remove the
measuring instruments and return the removed
parts.
2) Referring to "Testing of engine speed",

prepare for testing of the engine speed.
3) Run the engine at the rated output.
HD465-7R, HD605-7R 23
Bleeding air from fuel circuit 1 a The electric priming pump has a timer in it
to start and stop itself automatically (See
a Bleed air from the fuel circuit in the following the following figure).
cases according to this procedure. a The electric priming pump stops while the
q When the fuel filter is replaced lamp is blinking. This phenomenon is not
q When fuel is used up abnormal, however.
q When the engine is started for the first a If the switch is turned to the "OFF" position
time after the fuel piping or supply pump is while the lamp is blinking, the lamp goes
replaced off and the electric priming pump stops.
k While the electric priming pump is op-
a If the fuel filters were replaced, do not fill the
main filter and prefilter with the fuel. erating, pressure is applied to the fuel
circuit. Do not loosen the air bleeding
plug at this time, since the fuel may
1. Turn the starting switch to the "OFF" position.
spout out.
2. Check that the fuel valve on the fuel tank side
is open.
3. Turn lever (1) of the air bleeding piping to the

horizontal position to open the fuel circuit
valve.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a When performing air bleeding due to fuel
filter replacement, the air bleeding work is
completed now.
4. Turn "ON" switch (3) of electric priming pump
6. If the fuel was used up and air was sucked in
(2) installed in the left front fender.
the fuel system, or the fuel piping or supply
a The electric priming pump operates and
pump was replaced and there is not fuel in the
lamp (4) blinks.
fuel circuit, turn switch (3) "ON" again after the
electric priming pump stops automatically.
7. When lamp (4) goes off, the air bleeding work

is completed.
24 HD465-7R, HD605-7R
8. Turn lever (1) of the air bleeding piping to the Testing the fuel circuit for leakage1
vertical position to close the fuel circuit valve.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dan-
gerous since it can catch fire.
a After testing the fuel system or removing and
installing its components, check for fuel leak-
age according to the following procedure.
1. Spray color checker (developer) over the sup-

ply pump, common rail, injector, and joints of
the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
9. Start the engine with the starting motor.
k When starting the engine, check that there 3. Check the fuel piping and the devices for fuel
is no person around it. leakage.
a Do not operate the starting motor continu- a Check the high-pressure circuit parts con-
ously for more than 20 seconds. centrating on the areas coated with the
q After starting the engine, run it at low idle color checker, for fuel leakage.
for about 5 minutes to bleed all air from a If any fuel leakage is detected, repair it
the fuel circuit. and test again from step 1.
q Stop the engine and check that the air
bleeding valve is closed. 4. Run the engine at low idle.
10. If the engine does not start, try to start it again 5. Check the fuel piping and the devices for fuel
according to the following procedure. leakage.
k When starting the engine, check that there
a Check the high-pressure circuit parts con-
is no person around it. centrating on the areas coated with the
a Carry out the work with the air bleeding color checker, for fuel leakage.
valve closed. (Do not open the air bleed- a If any fuel leakage is detected, repair it
ing valve after step 7.) and test again from step 1.
a After the engine fails to start, wait for
about 2 minutes before trying to start 6. Run the engine at high idle.
again.
7. Check the fuel piping and the components for
1) Turn the electric priming pump switch ON.
fuel leakage.
2) While the electric priming pump is operat- a Check the high-pressure circuit parts con-
ing, crank the engine. centration on the areas coated with the
q If the engine does not start, repeat the color checker, for fuel leakage.
above operation. a If any fuel leakage is detected, repair it
a Do not operate the starting motor continu- and test again from step 1.
ously for more than 20 seconds.
a If the engine fails to start, wait for about 2 8. While keeping the engine speed at high idle,
minutes and try to start again. apply a load to the engine by stalling the
3) After starting the engine, run it at low idle torque converter or relieving the oil from the
for about 5 minutes to bleed all air from hydraulic pump.
the fuel circuit.
4) Stop the engine and check that the air 9. Check the fuel piping and the components for
bleeding valve is closed. fuel leakage.
5) After the above operation, start the engine a Check the high-pressure circuit parts con-
normally. centrating on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and test again from step 1.
a If any fuel leakage is not detected, inspec-
tion is completed.
HD465-7R, HD605-7R 25
Replacing and adjusting of fan 6. After tension pulley (7) moves in, replace fan
belts (8).
belt 1
a The fan belt tension usually does not need to
be adjusted, since the auto-tensioner is
installed.
a The procedures for replacing the belt and
adjusting the auto-tensioner after replacing the
belt are described here.
1. Loosen locknut (1) and adjustment bolt (2).
2. Remove 2 bolts (3).
3. Loosen bolt (4) to a degree that you can move

bracket (5). 7. After replacing the belt, loosen bolt (4), return
bracket (5) and install bolts (3).
8. Connect grease hose (6).
9. Adjust according to the following procedure.

1) Loosen bolts (3) and (4) to a degree that
you can move bracket (5).
2) Pull bracket (5) outward until it touches
tensioner pulley (7) and tighten adjust-
ment bolt (2) until its end touches the mat-
ing part.
3) After the end of adjustment bolt touches
the mating part, tighten it 2 more turns and
4. Push bracket (5) toward center line of the tighten locknut (1).
engine and tilt the bracket so that right end of 4) Tighten bolts (3) and (4) to fix bracket (5).
the bracket is positioned higher than left end
as shown in the drawing, then fix it with bolt
(4).
5. Disconnect grease hose (6) at (A) in the figure

and insert a bolt in tap hole (7) [Size: M12 ×
1.75] of the tension pulley and press it down
strongly with a bar etc.
26 HD465-7R, HD605-7R
Replacing and adjusting of

alternator and air conditioner
compressor belt 1
a The alternator and air conditioner compressor
belt tension usually does not need to be
adjusted, since the auto-tensioner is installed.
a The procedures for replacing the belt and
adjusting the auto-tensioner after replacing the
belt are described here.
1. Remove 8 bolts (1) and cover (2).
2. Loosen locknut (4) and tighten push bolt (3)

fully to push in tension pulley (5).
3. Replace belt (6).
4. Loosen push bolt (3) until it comes out by 90

mm and tighten locknut (4).
5. Install cover (2).
HD465-7R, HD605-7R 27

© 2007 KOMATSU
All Rights Reserved
28 HD465-7R, HD605-7R
SEN02529-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Testing torque converter stall speed ............................................................................................................... 3
Testing power train oil pressure ...................................................................................................................... 4
Adjusting transmission speed sensor ............................................................................................................11
Testing and adjusting brake oil pressure....................................................................................................... 12
Testing of accumulator nitrogen gas pressure and procedure for
charging accumulator with nitrogen gas ................................................................................................... 15
Testing brake performance ........................................................................................................................... 18
Bleeding air from brake circuit ...................................................................................................................... 20
Testing wear of front brake pad..................................................................................................................... 21
Testing wear of rear brake disc ..................................................................................................................... 22
Method of releasing parking brake in an emergency .................................................................................... 23
Testing and adjusting front suspension cylinder ........................................................................................... 24
Testing and adjusting rear suspension cylinder ............................................................................................ 28
Testing and adjusting front suspension cylinder (Automatic suspension specification) ................................ 32
Testing and adjusting hydraulic pressure in steering/hoist circuit ................................................................. 33
Testing and adjusting oil pressure in dump EPC circuit ................................................................................ 36
HD465-7R, HD605-7R 1
Air bleeding from steering cylinder................................................................................................................ 37

Procedure for raising dump body in emergency ........................................................................................... 38
Adjusting body positioner sensor .................................................................................................................. 39
Handling of high voltage circuit of engine controller...................................................................................... 40
Adjusting transmission controller .................................................................................................................. 40
Method for emergency escape at electrical system failure ........................................................................... 41
2 HD465-7R, HD605-7R
Testing torque converter stall 4. Depress the accelerator pedal gradually, run
the engine at high idle and stall the torque con-
speed 1 verter to raise the torque converter oil temper-
k Stop the machine on the level ground, turn ature.
k If the torque converter is stalled while
the gear shift indicator is indicating
"F1", the inside of the transmission
1. Turn the starting switch ON and set the monitor
may be broken. Accordingly, when
panel to the real-time monitoring function
stalling the torque converter, seat the
(REAL-TIME MONITOR) of the service mode.
body securely and check that the body
q Monitoring functions: 2 ITEMS
pilot lamp is turned OFF, and then set
q Monitoring code 1: 01002 (ENG SPEED)
the gearshift lever in the D position and
q Monitoring code 2: 30100 (T/C OIL TEMP)
check that the gearshift indicator is
a For the operation method, see "Special
indicating "F2".
functions of machine monitor".
5. When the torque converter oil temperature
goes above 90 °C, run the engine immediately
at low idle and return the gear shift lever to the
N position.
k Never operate the gear shift lever with
the accelerator pedal depressed. Oth-
erwise it may create a large shock and
may also become the cause of shorten-
ing the machine's service life.
6. Run the engine at a medium speed, and when

the torque converter oil temperature goes
down to approx. 80 °C, run at low idle.
2. Start the engine and raise the temperature of a Keep the gear shift lever at the "N" posi-
the torque converter oil and hydraulic oil. tion.
60 – 80 °C 7. Repeat Steps 3 – 6 and equalize the oil tem-
q Hydraulic oil temperature: 45 – 55 °C perature in the torque converter and transmis-
sion.
3. Turn the parking brake switch ON, depress the
brake pedal, then set the gear shift lever to the 8. At the same time as repeating Steps 3 and 4,
D position. inspect the stall speed when the torque con-
k If the gear shift lever is operated to any verter oil temperature is 80 °C.
position other than the D position, the a Inspect the stall speed 2 or 3 times.
machine may move off even if the a The stall speed may vary according to the
brake pedal is being depressed, so following conditions, so always inspect the
always inspect at the D position. stall speed at the time of delivery.
k Check that the gear shift lever pilot 1) Variations according to the engine se-
lamp indicates "2". rial number
Be sure to apply the parking brake, 2) Variations due to atmospheric pres-
check that the parking brake switch sure and temperature
lamp is lighting up, and seat the body. 3) Variations due to the torque con-
sumed by accessories
4) Variations due to characteristics of
the torque converter
5) Variations due to the method of in-
spection
HD465-7R, HD605-7R 3
Testing power train oil pressure 1
a Testing instrument a Table of oil pressure testing port positions

and gauges to use
No. Testing location Use a gauge
799-101-5002 Analog hydraulic meter (MPa{kg/cm²})
1
790-261-1204 Digital hydraulic meter 1 Main relief pressure 5.9{60}
K
799-101-5220 Nipple 2 Torque converter inlet port pressure 2.45{25}
2
07002-11023 O-ring 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}
a The transmission lubrication pressure is repre-

sented by the torque converter outlet port pres-
sure, so there is no need to test it.
4 HD465-7R, HD605-7R
k Stop the machine on a flat place, turn the Items related to torque converter
parking brake switch to the "PARK" posi-
tion and lock the tires with chocks. 2. Testing of torque converter inlet pressure
k When the body is raised, fix it with the lock 1) Raise the body and fix it with the lock pin.
pin securely. 2) Referring to "Testing of main relief pres-
k When removing and installing a plug or an sure", check that there is no abnormality.
oil pressure gauge from/to the measuring 3) Remove plug (2), install nipple K2 and
hole, stop the engine. connect oil pressure gauge [1] (2.45 MPa
k When removing and installing a plug or a {25 kg/cm²}) of hydraulic tester K1 by
testing instrument, stop the engine and hose [2].
wait until the oil temperature lowers thor-
oughly.
k When testing the oil pressure during travel,
secure a wide travel area and take extreme
care of the safety around the machine.
Items related to whole power train

1. Testing of main relief pressure
1) Raise the body and fix it with the lock pin.
2) Raise the transmission oil temperature.
a Oil leak tester for testing: 60 – 80 °C
3) Remove plug (1), install nipple K2 and
connect oil pressure gauge [1] (5.9 MPa
{60 kg/cm²}) of hydraulic tester K1 by
hose [2].
4) Start the engine and test the oil pressure

at high idle.
5) After finishing testing, remove the testing
instruments and return the removed parts.
4) Start the engine, set the gearshift lever in

the "N" position and test the oil pressure at
low idle and high idle.
HD465-7R, HD605-7R 5
3. Testing of torque converter outlet pressure 4. Testing of torque converter lockup clutch
1) Raise the body and fix it with the lock pin. pressure
2) Referring to "Testing of main relief pres- 1) Raise the body and fix it with the lock pin.
sure", check that there is no abnormality. 2) Remove plug (4), install nipple K2 and
3) Remove plug (3), install nipple K2 and connect oil pressure gauge [1] (5.9 MPa
connect oil pressure gauge [1] (2.45 MPa {60 kg/cm²}) of hydraulic tester K1 by
{25 kg/cm²}) of hydraulic tester K1 by hose [2].
hose [2].
3) Lower the body to the normal position.

4) Start the engine and test the oil pressure 4) Run the engine and raise the torque con-
at high idle. verter oil temperature to the operating
5) After finishing testing, remove the testing range.
instruments and return the removed parts. 5) Turn the parking brake switch to the "OFF"
position. While depressing the brake
pedal, set the gearshift lever in the "L"
position.
6) Release the brake, drive the machine at
high idle and test the oil pressure when
the lockup pilot lamp lights up.
k Since the F1 speed reaches about
11.5 km/h, take extreme care of the
safety around the machine.
6 HD465-7R, HD605-7R
Transmission related 5. Testing of transmission low clutch pres-

sure
a Table of gearshift lever positions, speed
1) Raise the body and fix it with the lock pin.
ranges, and clutches actuated
2) Remove plug (5), install nipple K2 and
Gearshift lever Speed Clutches connect oil pressure gauge [1] (5.9 MPa
R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R {60 kg/cm²}) of hydraulic tester K1 by
QQQQQQ F1 w q hose [2].
QQQQQQ F2 q q
QQQQQ F3 q w
QQQQ F4 w q
QQQ F5 w w
QQ F6 w q
Q F7 w w
Q N
Q R w q
a The Q mark indicates the speed ranges that

are actuated for each position of the gearshift
lever.
a The w mark and q mark indicate the clutches
that are actuated for each travel speed.
a The q mark indicates the speed range when
testing the oil pressure for each clutch.
3) Lower the dump body and set to the origi-

nal condition.
of the torque converter oil to the operating
range.
5) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set
the gearshift lever to position "L".
6) Release the brake and measure the oil
pressure when traveling at high idle.
k In F2, a maximum travel speed of
approx. 16.0 km/h is reached, so
check carefully that the surround-
ing area is safe.
7) After completing the testing, remove the
testing equipment and set to the original
condition.
HD465-7R, HD605-7R 7
6. Testing transmission Hi clutch 7. Testing transmission 1st clutch

1) Raise the body and fix it with the lock pin. 1) Raise the body and fix it with the lock pin.
2) Remove plug (6), install nipple K2 and 2) Remove plug (7), install nipple K2 and
connect oil pressure gauge [1] (5.9 MPa connect oil pressure gauge [1] (5.9 MPa
{60 kg/cm²}) of hydraulic tester K1 by {60 kg/cm²}) of hydraulic tester K1 by
hose [2]. hose [2].
3) Lower the dump body and set to the origi- 3) Lower the dump body and set to the origi-
nal condition. nal condition.
range.
range.
5) Turn the parking brake switch OFF, de-
5) Turn the parking brake switch OFF, de-
press the parking brake pedal, then set
press the parking brake pedal, then set
the gearshift lever to position "L".
the gearshift lever to position "3".
6) Release the brake and test the oil pres-
6) Release the brake, travel at high idle, and sure when traveling at high idle.
test the oil pressure when the gear shift
indicator shows "F3". k In F1, a maximum travel speed of
k In F3, a maximum travel speed of check carefully that the surround-
approx. 21.5 km/h is reached, so ing area is safe.
ing area is safe. 7) After completing the testing, remove the
7) After completing the measurement, re- condition.
move the testing equipment and set to the
original condition.
8 HD465-7R, HD605-7R
8. Testing transmission 2nd clutch and pilot 9. Testing transmission 3rd clutch and pilot
pressure pressure
hose [2]. hose [2].
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF de- 5) Turn the parking brake switch OFF, de-
press the parking brake pedal, then set press the parking brake pedal, then set
the gearshift lever to position 2. the gearshift lever to position "4".
6) Release the brake, travel at high idle, and
indicator shows "F4".
indicator shows "F2".
k
k
In F4, a maximum travel speed of
ing area is safe.
ing area is safe.
condition.
condition.
HD465-7R, HD605-7R 9
10. Testing transmission 4th clutch 11. Testing transmission R clutch

hose [2]. hose [2].
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, de- 5) Turn the parking brake switch OFF, de-
press the parking brake pedal, then set press the parking brake pedal, then set
the gearshift lever to position "6". the gearshift lever to position "R".
6) Release the brake and test the oil pres-
sure when traveling at high idle.
indicator shows "F6". k In R, a maximum travel speed of
k
ing area is safe.
ing area is safe. 7) After completing the testing, remove the
condition.
condition.
10 HD465-7R, HD605-7R
Adjusting transmission speed sensor 1
a Adjust the 3 speed sensors installed to the 3. Secure sensor (1) with lock nut (3).
transmission according to the following proce- 3 Lock nut: 49.0 – 68.6 Nm {5 – 7 kgm}
dure.
a Adjust all of the 3 speed sensors similarly.
(N1): Input shaft speed sensor
(N2): Intermediate shaft speed sensor
(N3): Output shaft speed sensor
1. Screw in sensor (1) until its tip lightly touches

tooth tip of gear (2).
a Check that the sensor tip is free from iron
dust and flaws before installing.
2 Threaded part: Gasket sealant (LG-5)
2. Return sensor (1) by 1/2 – 1 turn.

a At this time, clearance (a) between the
4. After finishing adjustment, check with the mon-
sensor tip and tooth tip or tooth end face
itoring function of the machine monitor that
of the gear is 0.75 – 1.0 mm.
each transmission shaft speed is displayed
normally.
a For details of the method of operation, see
"Special functions of machine monitor
(EMMS)".
HD465-7R, HD605-7R 11
Testing and adjusting brake oil 4) Test the cut-out pressure at high idle.
Read the ACC oil pressure (front or
pressure 1 q
rear) when it stops rising at the high-
a Testing instrument est point after the cut-in pressure.
(Testing with diagnosing devices)
799-101-5002 Analog hydraulic meter
K1 1) Stop the engine and remove plug (4) (18, P:
790-261-1204 Digital hydraulic meter 1.5). Connect nipple K3 and hose [1] and
K3 566-35-43561 Nipple install oil pressure gauge K1 (Oil pressure
gauge: 39.2 MPa {400 kg/cm²}).
1. Testing ACC accumlator charge oil pres-

sure
(Method using monitoring)
1) Set the machine monitor to the monitoring
function in the service mode and display
the following 2 items simultaneously.
q Monitoring code: 35500 (ACC OIL PRESS F)
q Monitoring code: 35501 (ACC OIL PRESS R)
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
2) Start the engine.

3) Test the cut-in pressure at high idle.
1] Depress and release the brake pedal
repeatedly to lower the oil pressure in
the accumulator.
2] Read the lower one of the ACC oil
pressures (front or rear) when it starts
rising after it reaches the bottom.
a For the method of testing, see "Method using

monitoring, 2) – 4)". (Read the pointer of the
oil pressure gauge, however.)
12 HD465-7R, HD605-7R
2. Testing rear brake operating pressure 4. Front brake operating pressure

1) Remove air bleeder (1) and install oil pres- 1) Remove air bleeder (3) and install Oil
sure gauge K1 [39.2 MPa {400 kg/cm²}]. pressure gauge (C1) [39.2 MPa {400 kg/
2) Operate the brake pedal and retarder con- cm²}].
trol lever and measure the oil pressure. 2) Operate the brake pedal and measure the
a After finishing testing, bleed air, refer- oil pressure.
ring to "Bleeding air from brake cir- a After finishing esting, bleed air, refer-
cuit" to see page 19. ring to "Bleeding air from brake cir-
cuit" to see page 19.
3. Testing parking brake releasing pressure
1) Remove air bleeder (2) and install Oil
pressure gauge K1 [39.2 MPa {400 kg/
cm²}].
2) Turn OFF the parking brake switch (Re-
lease the parking brake) and measure the
oil pressure.
a After finishing testing, bleed air, refer-
ring to "Bleeding air from brake cir-
cuit" to see page 19.
HD465-7R, HD605-7R 13
Adjusting
Adjusting charge valve cut-in pressure and cut-
out pressure
a If the charge valve cut-in pressure or cut-out
pressure is not normal, adjust the R1 relief
valve of charge valve (4) according to the fol-
lowing procedures.
a Both cut-in pressure and cut-out pressure
change by adjusting the R1 relief valve.
1. Remove the mudguard sheet in the left front

tire housing.
2. While holding adjustment screw (5), loosen

locknut (6).
3. Turn adjustment screw (5) to adjust the oil

pressure.
a Adjustment screw:
q When turned clockwise, the oil pres-
sure is heightened.
q When turned counterclockwise, the
oil pressure is lowered.
4. While holding adjustment screw (5), tighten

locknut (6).
3 Locknut: 10.2 Nm {1 kgm}
a After completing the adjustment, check
the oil pressure again following the proce-
dure for the above test.
14 HD465-7R, HD605-7R
Testing of accumulator nitrogen

gas pressure and procedure for
charging accumulator with
nitrogen gas 1
Symbol Part No. Part name Remarks
P1 792-610-1700 Gas charge tool —
792-610-1310 Nipple GOST

(For Russia)
792-610-1320 Nipple CGA No. 351

(For USA)
Nipple
P2 792-610-1330 (For USA) ASA B-571-1965
3. Connect gas charge tool P1 to valve (4) of
DIN 477-1963 accumulator (1) according to the following pro-
792-610-1350 Nipple NEN 3268-1966 cedure.
(For Germany) SIS-SMS 2235/2238
1) Turn handle (a) of gas charge tool P1 to
792-610-1360 Nipple (For UK) BS 341 Part 1-1962
the left until it stops.
Nitrogen gas cylinder (c) must be
k
q
Put on proper personal protective items connected even when you measure
(goggles, leather gloves and protective only the gas pressure.
clothes) so that the leaking nitrogen gas q Close the valve of nitrogen gas cylin-
will not touch your skin or clothes and work der (c) and handle (b).
on the windward side as long as possible. For connection of nitrogen gas cylin-
k
q
When handling nitrogen gas in a room or der (c) and gas charge tool P1, see
another place which is not ventilated well, "Procedure for charging accumulator
ventilate the work place forcibly and observe with nitrogen gas".
the Oxygen Deficiency Prevention Rules of
2) Connect gas charge tool P1 to valve (4) of
the Labor Safety and Sanitation Law.
k
accumulator (1).
Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accu-
mulator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
sured according to the following procedure, too.
1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is depress 30
times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from
accumulator (1).
HD465-7R, HD605-7R 15
4. Turn handle (a) of gas charge tool P1 to the left 3. Connect gas charge tool P1 and nitrogen gas
and read the gauge. cylinder (c) to valve (4) of accumulator (1)
a Since the indicated value varies with the according to the following procedure.
ambient temperature, correct it by the fol- 1) Turn handle (a) of gas charge tool P1 to
lowing formula. (The unit of each value in the left until it stops.
the formula is °C.) 2) Turn handle (b) to the left to open.
Indicated gas pressure = 3) Connect gas charge tool P1 to valve (4) of
Standard gas pressure x ((273 + t)/ accumulator (1).
(273 + 20))
4) Connect gas charge tool P1 and nitrogen
Standard gas pressure =
gas cylinder (c).
Indicated gas pressure/((273 + t)/
q There are 2 types of threads of nitro-
(273 + 20))
gen gas cylinders, W22-14 thread
t = Gas temperature at time of charge (°C)
(mail screw, type A) and W23-14
Reference: t may be assumed to be ambi-
thread (female screw, type B). When
ent temperature.
using a gas cylinder of W23-14 thread
(female screw, type B), connect the
5. If the gas pressure is too high or too low, adjust hose by using the adapter. (The
it referring to "Procedure for charging accumu- adapter is attached to gas charge tool
lator with nitrogen gas". P1.) [For Japan]
a Each time the pressure is measured, some q Use nipple P2 to connect the hose,
nitrogen gas is discharged and the pres- depending on the specification of the
sure lowers. Add nitrogen gas by the loss. nitrogen gas cylinder. [For overseas]
6. Remove gas charge tool P1 from accumulator

(1) and return the removed parts. See "Proce-
dure for charging accumulator with nitrogen
gas".
Procedure for charging accumulator with nitro-

gen gas
a The accumulator disconnected from the ma-
chine can be charged with nitrogen gas ac-
cording to the following procedure, too.
1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is depressed
30 times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from

accumulator (1).
4. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}.
5. After nitrogen gas starts flowing out of handle

(b), close handle (b).
16 HD465-7R, HD605-7R
6. Turn handle (a) slowly to the right to open

valve (4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged
and gas will leak. Accordingly, operate
handle (a) carefully.
7. Open the valve of nitrogen gas cylinder (c) fur-

ther to charge the accumulator with nitrogen
gas.
8. During the work, close the valve of nitrogen

gas cylinder (c) and check the nitrogen gas
pressure in the accumulator. 13. In a week after charging the accumulator with
a Since the indicated value varies with the nitrogen gas, check that the nitrogen gas pres-
ambient temperature, correct it by the fol- sure has not lowered.
lowing formula. (The unit of each value in a Check the functions in 5 minutes after
the formula is °C.) stopping the engine. (If the engine is
Indicated gas pressure = stopped for more than 5 minutes, the
Standard gas pressure x ((273 + t)/ brake circuit pressure lowers and the func-
(273 + 20)) tions cannot be checked accurately.)
Standard gas pressure = 1) Stop the machine on a level place and set
Indicated gas pressure/((273 + t)/ the parking brake switch to the "PARK"
(273 + 20)) position.
t = Gas temperature at time of charge (°C)
2) Start the engine and run it at medium
Reference: t may be assumed to be ambi-
speed for 1 minute and then stop it.
ent temperature.
3) Turn the starting switch to the ON position
and depress the brake pedal repeatedly.
9. After the accumulator is charged to the stan-
Count the number of depressing until the
dard pressure, close the valve of nitrogen gas
brake oil pressure caution lamp lights up.
cylinder (c).
q If number of depressing is less than
q If the accumulator is charged too much,
5: Accumulator gas pressure may
turn handle (b) to the left slowly with the
have lowered.
valve of nitrogen gas cylinder (c) closed to
q If number of depressing is 5 or more:
release the nitrogen gas gradually to
Accumulator gas pressure is normal.
adjust pressure.
10. Remove gas charge tool P1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool P1 and hoses.
3) Remove gas charge tool P1 from valve (4)
of the accumulator.
11. Apply soap water to valve (4) of the accumula-

tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
HD465-7R, HD605-7R 17
Testing brake performance 1 2. Testing braking performance of retarder

brake
k Stop the machine on the level ground and 1) Start the engine and turn the parking
turn the parking brake switch PARKING. brake switch OFF.
k If the machine starts to move, it can cause a
2) Pull the retarder lever fully, then set the
serious personal injury. Should the ma-
gear shift lever to the D position.
chine start moving during the performance
test, reduce the engine speed immediately,
move the gear shift lever to the N position
cating "F1", the inside of the trans-
and depress the foot brake.
mission may be broken.
Accordingly, when stalling the
1. Testing braking performance of foot brake torque converter, seat the body
(service brake) securely and check that the body
1) Start the engine and turn the parking pilot lamp is turned OFF, and then
brake switch OFF. set the gearshift lever in the D
2) Depress the brake pedal fully, then set the position and check that the gear-
gear shift lever to the D position. shift indicator is indicating "F2".
k If the torque converter is stalled 3) Depress the accelerator pedal gradually
while the gearshift indicator is indi- and check that the machine does not
cating "F1", the inside of the trans- move when the torque converter is stalled
mission may be broken. at the specified speed.
torque converter, seat the body
securely and check that the body
3) Depress the accelerator pedal gradually
and check that the machine does not
move when the torque converter is stalled
at the specified speed.
4) After completing the testing, run the

engine at low idle and set the gear shift
lever to the "N" position.
3. Testing braking performance of parking

brake
1) Turn the parking brake switch PARKING
and start the engine.
2) Set the gear shift lever to the D position.
4) After completing the test, run the engine at
low idle and set the gear shift lever to the
cating "F1", the inside of the trans-
"N" position.
mission may be broken.
torque converter, seat the body
securely and check that the body
18 HD465-7R, HD605-7R
3) Depress the accelerator pedal gradually

and check that the machine does not
move when the torque converter is stalled
at the specified speed.
a If the machine moves while the en-
gine speed is below the specified
speed, perform "Check of wear of
rear brake disc" described later.
4) After completing the testing, run the

engine at low idle and set the gear shift
lever to the "N" position.
HD465-7R, HD605-7R 19
Bleeding air from brake circuit 1
a If any brake circuit device was removed and

installed or if the transmission and brake cool-
ing oil was replaced, bleed air from the brake
circuit according to the following procedure.
k Stop the machine on a flat place, turn the
parking brake switch to the "PARKING"
position and lock the tires with chocks.
1. Rear brake
a Bleed air from the slack adjuster side first
and then bleed from the wheel brake side. 2. Parking brake
1) Using a vinyl tube for bleeding air, depress a Bleed air from the differential top block
the brake pedal and loosen air bleeder side first, then bleed air from the wheel
screw (1) or (2) by 3/4 turns. Keep de- brake side.
pressing the brake pedal until bubbles do 1) Using a vinyl tube for bleeding air, turn
not come out of the bleeder any more. OFF the parking brake switch (release the
When bubbles do not come out any more, parking brake) and loosen air bleeder
tighten (close) the bleeder and release the screw (4) by 3/4 turns.
pedal. 2) When bubbles do not come out of the
2) Pull the retarder control lever and loosen bleeder any more, tighten (close) the
air bleeder screw (1) or (2) by 3/4 turns. bleeder and turn PARKING the parking
Keep pulling the retarder control lever until brake switch.
bubbles do not come out of the bleeder 3) Bleed air from bleeder (5) on the wheel
any more. When bubbles do not come out side similarly to step 1) above.
any more, tighten (close) the bleeder and a After finishing bleeding air, tighten
release the retarder control lever. (close) the bleeder and put the cap.
3. Front brake
a Check that the front brake OFF 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.
20 HD465-7R, HD605-7R
Testing wear of front brake pad 1

– 566-98-41410 Gauge (Tool on machine)

1. Visual check
Visually check pad (1) for wear. If it is worn to
the end of wear limit line (a), replace it.
a The figure shows the left side as an exam-
ple.
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 inspection gauge
(b) 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 Since the pads on the right side and left side
are worn differently, check all of them.
HD465-7R, HD605-7R 21
Testing wear of rear brake disc 1

k Stop the machine on level ground, turn the
parking brake switch PARKING, and put
chocks under the tires.
k Carry out the inspection when the brake oil
temperature is less than 60 °C.
k When the disk comes close to the wear
limit, carry out the inspection more fre-
quently. 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.

a The figure shows the right side as an ex-
ample.
5. Install cap nut (1) of the gauge.

3 Cap nut: 128 – 186 Nm {13 – 19 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) is the wear
limit of the disc. If it is fully on the inside of
guide (3) (it reaches the end face), the
disc is worn to the limit. Replace the disc
in this case.
22 HD465-7R, HD605-7R
Method of releasing parking brake 3. After moving the machine, remove the parking
brake manual reset bolts and install plugs (1).
in an emergency 1 3 Tightening torque for plug:
a If the parking brake cannot be released be- 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
cause of a trouble in its electric or hydraulic
system, release it tentatively according to the
k If the hydraulic system has a trouble, the
wheel brake probably does not work nor-
mally. Accordingly, be sure to tow the
machine at low speed after releasing the
parking brake.
k 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.
k When releasing the parking brake, stop the
engine.
1. Remove plugs (1) (10 pieces).

a Prepare a container to receive the oil flow-
ing out of the plug holes.
2. Prepare 10 sets of bolt (2) (01017-51230),

washer (3), and nut (4) for releasing the park-
ing brake manually and tighten the bolts alter-
nately and evenly to release the parking brake.
a Tighten nuts (4) to pull piston (5) and
release the parking brake.
HD465-7R, HD605-7R 23
Testing and adjusting front

suspension cylinder 1
1 792-610-1000 Suspension tool
2 792-610-1130 Pump assembly
3 792-610-1110 Hose
4 792-610-1120 Joint
5 07020-21732 Fitting
6 792-610-1140 Joint
L 7 792-610-1250 Valve assembly a With the truck unloaded, starting switch ON,
8 792-610-1260 Nipple parking brake OFF, and hoist control lever at
9 792-610-1480 Stem the FLOAT position, check that the cylinder of
10 792-610-1640 Joint
the variable damper valve is in the soft mode.
a If the cylinder of the variable damper valve is
11 792-610-1400 Regulator assembly not in the soft mode when checking, operate
12 792-610-1430 Gauge as follows to switch to the soft mode.
13 792-610-1440 Gauge 1] Drive the machine several times repeat-
edly forward and in reverse to set to the
k Stop the machine on level ground, turn the soft mode using the retarder brake (Note
parking brake switch PARKING, and put 1).
chocks under the tires. (*1) If the foot brake pedal is used, the auto-
matic suspension is automatically set to
1. Testing length of cylinder the medium mode, and the resistance of
the cylinder increases, so it takes time to
1) Check that the bottom of the cylinder
adjust.
cover is within the range (e) marked by
arrows for the cylinder level.
2. Bleeding nitrogen gas
1) Set hydraulic jack [1] (490 kN {50 t}) under
the main frame.
2) Remove the cover from the suspension
cylinder.
3) Disconnect pressure sensor connector (2)
of oil level valve (1) and loosen oil level
valve (1) by 2 – 3 turns.
a The machine equipped with the pres-
sure sensor is shown in the figure. If
your machine is not equipped with the
pressure sensor, ignore the descrip-
tion on the pressure sensor.
a If the nitrogen gas is bled through
2) Before adjusting the oil level, check the intake valve (3), the valve core may
condition of the variable damper valve. be damaged. Accordingly, bleed
(For only automatic suspension specifica- through oil level valve (1).
tion) a Loosen only the oil level valve. Do
(S) posision: soft mode not loosen the pressure sensor and
(H) posision: hard mode nipple.
(M) posision: medium mode a When the oil level valve is loosened,
if both of the oil and gas spout out,
close the valve a little to bleed the gas
slowly.
24 HD465-7R, HD605-7R
4) Operate the hydraulic jack so that dimen- 7) After completion of supplying the oil, re-
sion (a) of the cylinder is the specified move the volume pump, then install feed
dimension for the oil level. valve (3).
Dimension (a): 79 ± 3 mm 3 Tightening torque of feed valve:
39.2 – 49.0 Nm {4 – 5 kgm}
3. Adjusting oil level

a Release the nitrogen gas before adjusting
the oil level.
1) Remove feed vavle (3), and install joint
L6.
2) Install fitting L5 to joint L4, then connect
hose L3 and volume pump L2.
3) Loosen air bleeding valve (4), then oper-
ate volume pump L2 until no more bub-
bles 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 Tightening torque of air bleeding
valve: 39.2 – 49.0 Nm {4 – 5 kgm}
5) Remove valve (1), then operate volume
pump L2 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 Tightening torque of oil level valve:
39.2 – 49.0 Nm {4 – 5 kgm}
HD465-7R, HD605-7R 25
4. Filling suspension cylinder with gas

k Put on proper personal protective items
(goggles, leather gloves and protective
clothes) so that the leaking nitrogen gas
will not touch your skin or clothes and work
on the windward side as long as possible.
k When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate t he w or k place f orcib ly and
observe the Oxygen Deficiency Prevention
Rules of the Labor Safety and Sanitation
Law.
1) Remove cap (5) from feed valve (3).
2) Set tool L as shown in the diagram.
a Before installing regulator L11, blow
the connector filter with nitrogen gas
at 0.98 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 L12
(internal pressure of gas cylinder).
a The pressure indicated must be at
least 0.98 MPa {10 kg/cm²} higher
than the pressure inside the suspen-
sion cylinder (max. pressure inside
suspension cylinder: 4.31 MPa {44
kg/cm²}).
4) Turn handle L11a of regulator L11 slowly
clockwise, set the pressure reading of
gauge L13 to 0.98 MPa {10 kg/cm²} above
the internal pressure of the suspension
cylinder, then operate valves L7 and L10
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
cylinders reaches the standard value, turn
handle L11a of regulator L11 counter-
clockwise to stop the flow of nitrogen gas.
a Standard dimension (a): 249 ± 10 mm
6) Fully turn handle L10a of L10 fully back
counterclockwise, loosen air bleeding plug
L7a of valve L7, release the gas inside the
hose, then remove tool L.
a Be careful not lose the O-ring of the
feed valve.
26 HD465-7R, HD605-7R
5. Adjusting installed length of cylinder a If there is any leakage of gas from the
a Carry out adjustment of the installed valve core, use tool [3] and replace
length of the cylinder with the machine the valve core.
unloaded and on level ground.
1) Drive the machine forward about 15 m
and stop it sharply and then drive it in
reverse and stop it sharply at the former
position. Repeat this cycle 3 - 4 times and
then stop the machine slowly without
depressing the brake pedal to eliminate
the sliding resistance of the cylinder (drag-
ging of the packing and bushing). Under
this condition, measure the installed
length.
a Do not use the foot brake but use the
retarder control lever to stop the
machine. After the machine stops, Note: 1. Check after replacement of oil or gas
check that the suspension is in the When the machine operates after the oil or
soft mode. gas is replaced, gas is dissolved in the
2) If the result of the check shows that the new oil in the replaced cylinder until the oil
installed length is too long, release nitro- is saturated. As a result, the gas volume
gen gas to adjust the length. is reduced and the installed length of the
a Loosen the valve (1) slightly to suspension may be reduced to below the
release the nitrogen gas. When limit. Accordingly, measure the installed
doi ng this, r eleas e only a smal l length of the suspension again 48 hours
amount of gas; do not make the cylin- after the oil or gas is replaced. If it is less
der move. than the specification value, adjust the
a If the nitrogen gas is bled so much gas.
that the cylinder will move, the in-
stalled length may be less than the 2. Checking for changes in installed
specified length. length caused by variation in ambient
a Do not press the tip of the valve core. temperature.
If the tip of the valve core is pressed, Depending on the ambient temperature
the valve core may be damaged. when the machine is working, the gas in
3) After releasing nitrogen gas and adjusting the suspension may expand or contract,
the installed length, repeat Step 1) to so the installed length will also change. In
check the installed length again. the operating sites where there are big dif-
4) Repeat the above Steps 1) – 3) to adjust ferences in temperature throughout the
the cylinder to the specified length. year, inspect daily and adjust to keep the
5) Finally, check that there is no leakage of installed length within the specified range.
gas from the valve core (6), valve (1), and
piston rod gland.
a Use soapy water to check for leakage
of gas.
HD465-7R, HD605-7R 27
Testing and adjusting rear 2. Releasing nitrogen gas

suspension cylinder 1 1) Set block [2] between the stopper and
axle housing.
a Testing instrument a Thickness of block: 19 mm
Symbol Part No. Part name Dimension (a) : 124 ± 3 mm
1 792-610-1000 Suspension tool
2 792-610-1130 Pump assembly
3 792-610-1110 Hose
4 792-610-1120 Joint
5 07020-21732 Fitting
6 792-610-1140 Joint
L 7 792-610-1250 Valve assembly
8 792-610-1260 Nipple
9 792-610-1480 Stem
10 792-610-1640 Joint
11 792-610-1400 Regulator assembly
2) Disconnect pressure sensor connector (2)
12 792-610-1430 Gauge of valve (1), then loosen the valve 2 – 3
13 792-610-1440 Gauge turns.
a When releasing the nitrogen gas,
k Stop the machine on level ground, turn the there is danger that releasing the gas
parking brake switch PARKING, and put from the valve core of feed valve (3)
chocks under the tires. will damage the valve core, so
a When checking, stop the unload machine on a remove the gas at the valve (1).
flat place. a When loosening the valve (1), loosen
1. Testing length of cylinder only the valve itself. Do not loosen the
1) Remove dust cover. pressure sensor or nipple.
k When loosening the valve (1),
2) Check that dimension (a) of the rear sus-
gradually loosen only valve (1) it-
pension cylinder is within the specified
self, and do not remove the valve
value.
until all the nitrogen gas has been
Specified value for dimension (a) :
released from the slit.
k If the nitrogen gas has not all been
204 ± 10 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.
a The standard dimension is described on

the decal stuck on the cylinder, too.
28 HD465-7R, HD605-7R
4. Filling suspension cylinder with gas

k Put on proper personal protective items
(goggles, leather gloves and protective
clothes) so that the leaking nitrogen gas
will not touch your skin or clothes and work
on the windward side as long as possible.
k When handling nitrogen gas in a room or
another place which is not ventilated well,
vent ilat e th e w ork p lace fo rcibly and
observe the Oxygen Deficiency Prevention
Rules of the Labor Safety and Sanitation
Law.
1) Remove cap (5) from feed valve (3).
3. Adjusting oil level 2) Set tool L to the feed valve supply as
a Release the nitrogen gas before adjusting shown in the diagram.
the oil level. a Before installing regulator L11, blow
the filter in the connector with nitro-
1) Remove feed valve (3), and install joint
gen gas at 0.98 MPa {10 kg/cm²} or
L6.
more to blow out all dirt or dust. (Dirt
2) Install fitting L5 to joint L4, then connect or dust in the system causes failures.)
hose L3 and volume pump L2.
3) Open valve [2] of the gas cylinder [1], and
3) Loosen air bleeding valve (1), then oper- check the pressure reading of gauge L12
ate volume pump L2 until no more bub- (internal pressure of gas cylinder).
bles come out with the oil from air a The pressure indicated must be at
bleeding valve (1). least 0.98 MPa {10kg/cm²} higher
4) When no more bubbles come out with the than the pressure inside the cylinder
oil, tighten air bleeding valve (1). (max. pressure inside cylinder: 2.74
5) After adding oil, remove the volume pump, MPa {28 kg/cm²}).
then install feed valve (3). 4) Turn handle L11a of regulator H11 slowly
clockwise, set the pressure reading of
gauge L13 to 0.98 MPa {10kg/cm²} above
the internal pressure of the cylinder, then
operate valves L7 and L10 to fill the cylin-
der with nitrogen gas.
a Fill the left and right cylinders in the
same way.
5) When dimension (a) of the left and right
cylinders reaches the standard value, turn
handle L11a of regulator L11 counter-
clockwise to stop the flow of nitrogen gas.
a Standard dimension (a) :
204 ± 10 mm
HD465-7R, HD605-7R 29
6) Fully turn handle L10a of L10 counter- the packing and bushing). Under this con-
clockwise, loosen air bleeding plug L7a of dition, measure the installed length.
valve L7, release the gas inside the hose, a Do not use the foot brake when brak-
then remove tool L. ing the machine. Use the retarder
a Be careful not to lose the O-ring of the control lever to brake, the machine,
feed valve. then check that the suspension is in
the soft mode.
2) If the result of the check shows that the
installed length is too long, release nitro-
gen 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 bled so much
t h at t he c y l i n d e r wi l l m o v e , t h e
installed length may be less than 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 pis-
ton rod gland.
a Use soapy water to check for leakage
of gas.
a If the gas leaks through the valve
core, replace the valve core with tool
[3].
2 Valve core: Adhesive
3 Valve core:
16.7 – 34.3 Nm {1.7 – 3.5 kgm}
5. Adjusting installed length of cylinder

a Carry out adjustment of the installed
length of the cylinder with the machine
empty and on level ground.
1) Drive the machine forward about 15 m
and stop it sharply and then drive it in
reverse and stop it sharply at the former
position. Repeat this cycle 3 – 4 times
and then stop the machine slowly without
pressing the brake pedal to eliminate the
sliding resistance of the cylinder (hitch of
30 HD465-7R, HD605-7R
6. Testing and adjusting dust cover

a Check the cover for damage caused by
stones etc. scattered by the tires during
travel and repair or replace it, if necessary.
1) Check visually that there are no cracks or
breaks in cover (1).
a If the cover is damaged, replace it
with a new part.
2) Check that hooks (2) are not missing. (3
places)
a If any hooks are missing, remove all
mud and dirt, then install hooks.
3) Check that band (3) is not loose or miss-
ing.
a If the band is loose or missing, tighten
to the following torque.
3 Band:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
HD465-7R, HD605-7R 31
Testing and adjusting front

suspension cylinder
(Automatic suspension specifica-
tion) 1
1. Testing
1) Check that length (a) of hydraulic cylinder
(1) is as specified under the following con-
dition.
a Condition (Mode Soft)
1] Machine is empty.
2]: Starting switch is ON.
3] Parking brake switch is PARKING.
4] Work equipment control lever is at
FLOAT.
a Specified length (a): 352 ± 1 mm
2) Shift the hoist lever from the FLOAT posi-
tion to another position and check that
hydraulic cylinder length (a) is not (is
longer minimum) 352 ± 1 mm.
2. Adjusting
1) Remove mounting bolt (2) of hydraulic cyl-
inder (1) and disconnect hydraulic cylinder
(1).
2) Loosen locknut (3) and adjust mounting
length (a) with rod end. 5) Check that the hole of bracket (5) is in the
a Specified length (a): 352 ± 1 mm slit (part (e)) in modes Soft and Medium.
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 minimum) 352 ± 1 mm.
(Reference)
q (b) in hard mode: 383 ± 1 mm
q (d) in medium mode: 414 ± 1 mm
32 HD465-7R, HD605-7R
Testing and adjusting hydraulic

pressure in steering/hoist circuit 1
K1
799-261-1204 Digital hydraulic meter

k When testing and adjusting, lower and seat
the body to the frame, stop the engine and 2. Adjusting hydraulic pressure in steering
remove the hydraulic tank cap to release circuit
the residual pressure in the cylinder circuit. If the hydraulic pressure is not within the stan-
k When operating the steering wheel, check dard value, adjust as follows.
that there is nobody around the front tires. q Steering pressure (adjust with demand
valve)
1) Remove cap (2) of relief valve, then loos-
Steering circuit
en locknut (3) and turn adjustment screw
1. Measuring hydraulic pressure in steering (4) to adjust.
circuit a To INCREASE pressure, turn CLOCK-
1) Raise the hydraulic oil temperature. WISE
a Oil temperature when measuring : To DECREASE pressure, turn COUN-
45 – 55 °C TERCLOCKWISE
2) Remove plug (1) and install tool K1 (39.2 a One turn of the adjustment screw ad-
MPa {400 kg/cm²}). justs by 2.43 MPa {24.8 kg/cm²}.
3) Start the engine, turn the steering wheel
fully to the right or left to relieve the oil and
measure the oil pressure at this time.
2) After adjusting, hold the adjustment screw

(4) with a screwdriver to prevent it from
turning, then tighten the locknut (3) and
install the cap (2).
HD465-7R, HD605-7R 33
3) Check again so that the hydraulic pres- Hoist circuit

sure is within the specified value.
For details, see "Measuring hydraulic 1. Testing hydraulic pressure in hoist circuit
pressure in steering circuit". 1) Raise the hydraulic oil temperature.
a The pressure of crossover relief valve a Oil temperature when measuring :
(5) cannot be adjusted when it is 45 – 55 °C
installed on the machine, so do not 2) Remove oil pressure measuring hole plug
adjust the pressure. (1) and install tool K1 (39.2 MPa {400 kg/
cm²}).
3) Operate the hoist control lever, and move
the dump body to the maximum dump
position to relieve the circuit, then mea-
sure the hydraulic pressure with the
engine at full throttle.
3. Testing steering valve charge pressure

1) Remove plug (6) and install tool K1 (39.2
MPa {400 kg/cm²}).
2) Test in the same way as when measuring
the hydraulic pressure in the steering cir-
cuit.
4. Testing hydraulic pressure in steering cyl-

inder
1) Remove pressure measuring hole plug (7)
(when turning the steering to the left) or
pressure measuring hole plug (8) (when
turning the steering to the right), and
install tool K1 (39.2 MPa {400 kg/cm²}).
the hydraulic pressure in the steering cir-
cuit.
34 HD465-7R, HD605-7R
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 ad-
justs by 4.2 MPa {42.8 kg/cm²}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turn-
ing, then tighten the locknut.
3 Tightening torque of lock nut:
29.4 – 39.2 Nm {3 – 4 kgm}
3) Check again so that the hydraulic pres-
sure is within the specified value.
For details, see "Testing hydraulic pres-
sure in hoist circuit".
3. Testing hoist cylinder pressure

1) Remove plug (4) and install tool K1 (39.2
MPa {400 kg/cm²}).
the hydraulic pressure in the hoist circuit.
HD465-7R, HD605-7R 35
Testing and adjusting oil pressure 1) Disconnect EPC hose (3) or (4) to be mea-
sured.
in dump EPC circuit 1 (3): Dump raise side (Port PB)
a Testing instrument (4): Dump lower side (Port PA)

1
799-261-1204 Digital hydraulic meter
K 4 799-101-5230 Nipple
799-401-3100 Adapter
5
02896-11008 O-ring
k Loosen the oil filler cap of the hydraulic

tank slowly to release the residual pressure
from the tank.
Testing 2) Install adapter (K5) to hoist valve and con-

nect the hose.
1. Testing dump EPC valve main pressure 3) Install nipple [1] and hose [2] and connect
1) Remove oil pressure measuring hole plug oil pressure gauge K1 [5.9 MPa {60 kg/
(2) (M14 × 1.5) from dump EPC valve (1) cm²}].
inside the hydraulic tank (inside the 4) Start the engine, set the dump lever to the
machine). RAISE, FLOAT or LOWER position and
test the circuit oil pressure at this time.
2) Install nipple K4 and hose [2] and connect

oil pressure gauge K1 [5.9 MPa {60 kg/
cm²}].
3) Start the engine and test the oil pressure
when the dump lever is in neutral.
2. Testing dump EPC valve output pressure
36 HD465-7R, HD605-7R
Air bleeding from steering

cylinder 1
k 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 sec-
onds 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 a speed of
about 30 rpm to the right and left steering
cylinder stroke ends repeatedly.
4) Turn the steering wheel as quickly as pos-
sible to the left and right to the end of the
steering cylinder 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 direc-
tion.
HD465-7R, HD605-7R 37
Procedure for raising dump body 4. When lowering the dump body, remove plug
(2) and tighten tool M slowly.
in emergency 1
k When performing this procedure, be
a Testing instrument sure not to go under the dump body
but stand on the ground.
a The dump body lowers by itself. Keep it at
M 792T-491-1110 Plug safe lowering speed by adjusting the tight-
ening depth tool M.
a If the dump body cannot be raised because of
a failure in the controller or electric system, 5. After the dump body lowers completely, re-
raise it to dump the load according to the fol- move tool M and install plug (2).
lowing procedure. 3 Tightening torque of plug:
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 screw in tool M fully.

a If tool M is screwed in fully, the spool is
moved to the rising stroke end.
1) If the engine can be started, start the en-

gine 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 steer-
ing pump continuously for more than
90 seconds. If the load cannot be
lowered in 90 seconds, stop and cool
the steering pump and then operate it
again.
3. Stop the engine and remove tool M and install

plug (1).
3 Tightening torque of plug:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
38 HD465-7R, HD605-7R
Adjusting body positioner sensor1 a Adjust the input voltage as follows.

q INCREASE link length to DE-
k Stop the machine on the level ground, turn CREASE voltage
the parking brake switch PARKING, and set q DECREASE link length to IN-
chocks to the tires. CREASE voltage
a If the body positioner rod has been discon- 4) Install mounting bolt (2).
nected and connected again or the body posi- 5) Tighten locknut (1).
tioner sensor has been removed and installed 6) Check that the sensor input voltage is nor-
again, inspect and adjust the body positioner mal.
sensor as follows.
1. Checking sensor input voltage

1) Switch the machine monitor display to the
monitoring function of service mode and
display the body positioner sensor input
voltage.
a Monitoring system: BRAKE
a Monitoring code:
34602 (BODY POSSITION)
3. Caribrating system
k Stop the machine on the level ground,
turn the parking brake switch PARK-
ING, and set chocks to the tires.
a Hydraulic oil temperature: 80 – 90 °C
1) Run the engine and raise the hydraulic oil

temperature to 80 – 90 °C.
2) Lower the dump body to the stroke end
and keep the control lever in the "Float"
position for 5 seconds.
a Check that body pilot lamp is turned
2) Start the engine. OFF.
3) Operate the dump lever and check the 3) Raise the dump body to the stroke end
monitoring voltage when the dump lever is and keep the control lever in the "Raise"
operated fully to the LOWER position and position for 5 seconds while running the
RAISE position. engine at low idle.
a When operated fully to LOWER: 4) Lower the body. Raise the body while run-
0.46 – 0.54 V ning the engine at high idle and then lower
a When operated fully to RAISE: and seat it with the lever in the "Float"
4.00 – 4.70 V position while running the engine at low
idle. Repeat this operation 5 – 10 times.
2. Adjusting link length a Move the control lever to the raise
a If the monitoring voltage is not within the stroke end and float stroke end.
normal range, adjust the length of the link 5) Raise the body while running the engine
as follows. at high idle and then lower and seat it with
1) Loosen locknut (1). the control lever in the "Float" position
2) Remove mounting bolt (2). while keeping the engine speed at high
3) Turn rod end (3) to adjust the length of the idle. Repeat this operation 5 – 10 times.
link (4). a Move the control lever to the raise
a Standard installed length (a) of link: stroke end and float stroke end.
440 mm
a Do not reduce length (a) to below 436
mm.
HD465-7R, HD605-7R 39
Handling of high voltage circuit of Adjusting transmission

engine controller 1 controller 1
1. Disconnecting or connecting operation of the a After any of the following operations, adjust the
connector between the engine controller and transmission in order to tune the feeling of
the engine shall be performed only when the transmission and its controller.
starting switch is in the OFF position. q The transmission has been overhauled or
replaced.
2. Do not start the engine while the T adapter is q The transmission control valve has been
in ser ted or c onnec ted to the conn ector repaired or replaced.
between the engine controller and the engine q The transmission controller has been replaced.
for diagnosis. q Power train speed sensor has been repaired or
a You may turn the starting switch to the replaced.
OFF or ON position but must not turn it to q The transmission oil temperature sensor has
the START position. been repaired or replaced.
q The transmission oil filter has been clogged
abnormally and repaired.
a For the adjusting operation of the transmission,
use the service function of the machine moni-
tor.
a For the details of the operation method, see
" Sp e c i a l f u n c t i o n s o f m a c h i n e m o n i t o r
(EMMS)".
40 HD465-7R, HD605-7R
Method for emergency escape at electrical system failure 1

If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the
machine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor (EMMS)" for the method of checking the failure
code.
Note: If the engine cannot be started and the machine is towed, release the parking brake temporarily refer-
ring to "Method for emergency release of parking brake", since it cannot be released by operating the
switch.
HD465-7R, HD605-7R 41
2. When transmission control system has a trouble and machine cannot start
a Check the failure code and select a proper escape procedure from the following table.
a For the method of checking the failure code, see "Special functions of machine monitor".
Failure Condition when Starting gear speed set with lever

Escape method Remarks
code trouble occurred position after escape operation
1500L0 Occurrence condition 2 Escape procedure 2 — Occurrence condition 1

Gear speed is kept fixed and
15G0MW Occurrence condition 2 Escape procedure 3 D – L: F2 gear is not shifted from fixed
gear after machine restarts.
15H0MW Occurrence condition7 Escape procedure1 D – L: F2, R: R If lever is set to N position,
gear is set in neutral.
15J0MW Occurrence condition7 Escape procedure1 D – L: F2, R: R
Occurrence condition 2
15K0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R Gear is set in neutral sud-
denly during travel. Once
15L0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R machine stops travel, gear is
kept in neutral and machine
15M0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R does start when lever is
operated.
15N0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R
15SBL1 Occurrence condition7 Escape procedure1 R: R Gear is set in neutral sud-
denly during travel.
15SBMA Occurrence condition2 Escape procedure1 D – L: F2 Occurrence condition 4
After engine is started, gear
15SCL1 Occurrence condition7 Escape procedure1 D – L: F2, R: R is kept in neutral and
machine does not start when
15SCMA Occurrence condition7 Escape procedure1 D – L: F2, R: R lever is operated.
15SDL1 Occurrence condition7 Escape procedure1 D – L: F2, R: R Occurrence condition 5

Lever responds abnormally
15SDMA Occurrence condition7 Escape procedure1 D – L: F2, R: R and does not work. If lever is
operated, gear is set in neu-
15SEL1 Occurrence condition7 Escape procedure1 D – L: F1 tral.
15SEMA Occurrence condition7 Escape procedure1 D – L: F2, R: R Gear speed is kept fixed and
gear is not shifted from fixed
15SFL1 Occurrence condition7 Escape procedure1 D – L: F2 gear after machine restarts.
If lever is set to N position,
15SFMA Occurrence condition7 Escape procedure1 D – L: F1, R: R gear is set in neutral but can-
not be shifted any more.
15SGL1 Occurrence condition7 Escape procedure1 D – L: F4
15SGMA Occurrence condition7 Escape procedure1 D – L: F2, R: R Proper clutch for travel is
used and gear speed is
fixed. If there is not proper
15SHL1 Occurrence condition7 Escape procedure1 D – L: F6 clutch, gear is set in neutral.
If lever is set to N position,
15SHMA Occurrence condition7 Escape procedure1 D – L: F2, R: R gear is set in neutral.
15SJMA Occurrence condition1 Escape procedure1 D – L: F2, R: R Note 1
Even if trouble disappears,
If display becomes normal, machine gear is kept in neutral until
DAQ0KK Occurrence condition1 Escape procedure5 lever is set to N position
can travel normally (Note 1).
once.
If display becomes normal, machine
DAQ2KK Occurrence condition1 Escape procedure4
DAQ9KQ Occurrence condition4 Escape procedure6 —

DAQRKR Occurrence condition2 Escape procedure5
DAQRMA Occurrence condition4 Escape procedure1 D – L: F2, R: R
DB2RKR Occurrence condition1 Escape procedure1 D – L: F2, R: R
DDTHKA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DDTJKA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DDTKKA Occurrence condition1 Escape procedure1 D – L: F1
42 HD465-7R, HD605-7R
Failure Condition when Starting gear speed set with lever

Escape method Remarks
code trouble occurred position after escape operation
DDTLKA Occurrence condition1 Escape procedure1 D – L: F2 See the "Remarks" of a front

page
DDTMKA Occurrence condition1 Escape procedure1 D – L: F4
DDTNKA Occurrence condition1 Escape procedure1 R: R
DDTPKA Occurrence condition1 Escape procedure1 D – L: F6

DF10KA Occurrence condition5 Escape procedure7
DF10KB Occurrence condition5 Escape procedure7 If display becomes normal, machine

DLF1KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLF1LC Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLF2KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLF2LC Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLT3KA Occurrence condition6 Escape procedure3 D – L: F2, R: R
DXH1KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH1KB Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH1KY Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH4KY Occurrence condition7 Escape procedure1 D – L: F1
DXH7KA Occurrence condition7 Escape procedure1 D – L: F2
DXH7KB Occurrence condition7 Escape procedure1 D – L: F2
DXH7KY Occurrence condition7 Escape procedure1 R: R
DXHHKA Occurrence condition7 Escape procedure1 D – L: F2, R: R
DXHHKB Occurrence condition7 Escape procedure1 D – L: F2, R: R
DXHHKY Occurrence condition7 Escape procedure1 D – L: F6
HD465-7R, HD605-7R 43
Escape procedure 1:
1. Stop traveling and return the gearshift lever to
the "N" position.
2. Operate the gearshift lever again and move
the machine off.
a When operating the gearshift lever, release
the accelerator pedal.
a N o D – L or N o R
Escape procedure 2:
Tow the machine.
a If the engine cannot be started and the machine
is towed, the parking brake cannot be released
by operating the switch, so carry out the opera-
tion to release it temporarily. For details, see
"Method for emergency release of parking
brake".
Escape procedure 3:
1. Stop traveling and return the gearshift lever to
the "N" position.
2. Connect and disconnect emergency escape
connectors A1 (female) and A2 (male), and
switch to the emergency escape mode.
a Connectors A1 and A2 are installed to
near the fuse box.
a Connect and disconnect the connectors
with the starting switch at ON or with the
engine started.
3. Operate the gearshift lever again and move
the machine off.
a When operating the gearshift lever, release
the accelerator pedal.
a N o D – L or N o R
a The emergency escape mode is main-
tained until the starting switch is turned
OFF.
Escape procedure 4:
Check the circuit breaker and fuse. If they are nor-
mal, replace the transmission controller.
q Circuit breaker: No. 64 "FUB2" No. 65 (80 A)
q Fuse: BT3-No. 14 (10 A)
Escape procedure 5:
Check the circuit breaker and fuse. If they are nor-
mal, replace the transmission controller.
q Circuit breaker: "FUA2" (30 A)
Escape procedure 6:
Check the model selection setting. If it is normal,
see adjustment of transmission controller.
Escape procedure 7:
Check the fuse. If it is normal, replace the gearshift
lever.
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45

© 2007 KOMATSU
All Rights Reserved
46 HD465-7R, HD605-7R
SEN02530-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Setting and adjusting of devices ..................................................................................................................... 2
Special functions of machine monitor (EMMS) ............................................................................................. 14
HD465-7R, HD605-7R 1
Setting and adjusting of devices 1

Items to be set or adjusted after replacement, disassembly, assembly or additional installation of
controllers or sensors
a If any of the following devices or parts is replaced, disassembled, assembled or installed additionally,
carry out the necessary setting and adjusting.
Device/Option replaced,
disassembled,
Necessary setting/adjusting
assembled or installed
additionally
Setting of model selection (See 1-1 of this section)
Setting of option selection (See 1-2 of this section)
Setting of machine monitor (corrosion resistor) in OFF (See 1-3 of this section)
Machine monitor
Deletion of information of electrical equipment system fault history (See *2-1)
Setting of service meter (See *3-1)
Setting of reverse travel odometer (See *3-2)
Adjusting of transmission ECMV current (See *2-2)
Transmission
Resetting and execution of transmission initial learning (See *2-2)
Transmission controller Adjusting of transmission ECMV current (See *2-2)
Resetting and execution of transmission initial learning (See *2-2)
Transmission ECMV Adjusting of transmission ECMV current (See *2-2)
solenoid Resetting and execution of transmission initial learning (See *2-2)
Retarder controller Setting of option selection (See 1-2 of this section)
Body positioner sensor
Adjusting of body positioner sensor (See *2-3)
Body positioner rod
VHMS Initialization procedure for VHMS controller
ORBCOMM controller Setting of ORBCOMM
Payload meter in VHMS
Initialization procedure for VHMS controller
Initialization and after-replacement setting of card-type payload meter
Card-type payload meter
Initialization procedure for VHMS controller (if VHMS is installed)
Optional device Setting of option selection
*2-1: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([10]
Electrical equipment system fault history display function).
*2-2: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([15]
Adjusting function).
*2-3: For the setting and adjusting procedure, see "Adjusting of body positioner".
*3-1: For the setting and adjusting procedure, see Service News.
*3-2: For the setting and adjusting procedure, see Service News.
1
2 HD465-7R, HD605-7R
1-1. Setting of model selection 4) Displaying service menu selection screen

1. Switching to service mode After confirming all ID's of 4 digits, display
1) Confirming the screen display the service menu selection screen in the
Check that the machine monitor is in oper- service mode.
ator mode and the screen is displaying a By inputting and determining the ID
either the "service meter and integrated once, it will be effective until the start-
odometer", "action code" or "failure code". ing switch is turned OFF.
2) Displaying ID input screen
Press the following 2 switches at the same
time for longer than 5 seconds to display
the ID input screen.
q [t] switch and [<] switch
a If the switch is pressed for longer than
5 seconds, the character display sec-
tion becomes blank. After confirming
this condition, release the switch.
2. Selecting and determining service menu

1) When pressing the [>] switch or [<] switch
in the service menu selection screen, the
service menu is displayed endlessly in the
order shown in the below table, so select
the model selection function (MACHINE).
q [>]: To proceed to next service menu.
q [<]: To return to previous service menu.
a Displayed service menu:
3) Input and determination of ID
After displaying ID input screen, operate Display Function
[>], [<], [U], and [t] switch to input 4 dig- ELECTRIC FAULT
Electrical system failure history
its ID. display function
a ID: 6491 Mechanical system failure history
MACHINE FAULT
display function
q [ > ]: Number at the cursor increases.
[ < ]: Number at the cursor decreases REAL-TIME
q Real-time monitoring function
MONITOR
q [U]: Number at the cursor is deter-
CYLINDER
mined CUT-OUT
Cylinder cut-out mode function
q [t]: Cursor moves to left end or the
NO INJECTION No injection cranking function
display returns to operator mode
TUNING Adjusting function
screen.
MAINTENANCE Filter and oil replacement time setting
a If the ID input screen is left without MONITOR function
switch operation for longer than 60
OPERATION INFO Operation information display function
seconds, it automatically returns to
FIX POWER
the operator mode screen. MODE
Engine mode fixing function
SNAPSHOT Manual snap shot function
PLM PLM (Payload meter) setting function
OPTIONAL
Option selection function
SELECT
MACHINE Model selection function
Initialize function
INITIALIZE
(exclusive function for factory)
HD465-7R, HD605-7R 3
a As for the use of the service menu, 3. Selecting and setting of model
besides model selection function, 1) When pressing the [>] switch or [<] switch
option selection function, and filter in the model selection setting screen, the
and oil replacement time setting func- model which can be set is displayed end-
tion (part of function), refer to the sec- lessly in the order shown in the below
tion of "Special function of machine table, so select the applied model.
monitor". q [>] switch: To proceed to next model
a [<] switch: To return to previous model
*
In the " " part, the model presently
set is displayed.
q
a Displayed model:
a Even if the model presently set is cor- Display Model
rect, be sure to carry out the setting
HD785 HD785-7
newly.
HD605 HD605-7E0, HD605-7R
HD465 HD465-7E0, HD465-7R
HD405 HD405-7
HD325 HD325-7
2) After selecting the model in the model

selecting screen, determine the model by
pressing the [U] switch.
q [U]: Determine the setting.
q [ t]: To cancel the setting
a The below figure shows the example
that HD465-7R has been selected.
2) After selecting the model selection func-

tion, press [U] switch for longer than 5
seconds and display the model selection
setting screen.
q [U]: Conduct the service menu.
a Press [U] switch for longer than 5
seconds, otherwise it will not change
to model selection setting screen.
a In the model selection setting screen,
display only the model to be set at the
[*] part.
4 HD465-7R, HD605-7R
4. Storing data in controller

1) After determining the model selection set-
ting, check that the display automatically
returned to the service menu screen and
the selected model is surely displayed.
2) Turn the starting switch OFF and keep

that condition for longer than 15 seconds.
a Unless the starting switch is turned off
for longer than 15 seconds, the new
data is not memorized in the control-
ler.
3) Turn the starting switch ON again.
a After this operation the model setting
becomes effective.
5. Carrying out option setting

If once carrying out the model selection set-
ting, all setting of option selection is reset, so
continue to carry out the setting of option
selection.
a Refer to section "1-2. Setting of option
selection".
HD465-7R, HD605-7R 5
1-2. Setting of option selection

a Item list of option selection function
Item Display Code Default setting Contents of selection
ARSC ARSC 02 Added (ADD) If ARSC is installed, select ADD.
ASR ASR 03 Not added (NO ADD) If ASR is installed, select ADD.
ABS ABS 04 Not added (NO ADD) If ABS is installed, select ADD.
Auto-suspension AUTO SUS 05 Added (ADD) If auto-suspension is installed, select ADD.
Select from following.
• VHMS is not installed: [NON]
VHMS/PLM VHMS/PLM 07 VHMS+PLM
• Only VHMS: [VHMS]
• VHMS + Built-in PLM: [+PLM]
— — 09 E1 Selecting operation is prohibited (Fixed to E1).
— — 10 Not added (NO ADD) Selecting operation is prohibited (Fixed to NO ADD).
Set speed compensation valve for tire size.
HD465-7R : 0 %
HD605-7R : 0 %
Tire size
TIER SIZE 12 0% • If speedometer reading is not correct, adjust it with
compensation
this item.
• If setting is increased by 1%, reading is increased
by 1% at 0%.
If inclinometer (machine lateral inclination sensor) is
Inclinometer INCLINOMET 13 Added (ADD)
installed, select ADD.
Front brake cut F BRAKE CUT 14 Added (ADD) If front brake cut function is installed, select ADD.
Set unit of speed as follows.
• When MPH is used: MPH
Unit selection • When km/h is used: km/h
SPEED (UNIT) 15 MPH
(MPH / km/h) a This item is not displayed in the case of machine
with SI specification.
a Do not change this setting, basically.
Maintenance
SENSOR 19 Not added (NO ADD) If maintenance sensor is installed, select ADD.
sensor
1. Switching to service mode

Switch to the service mode by referring to "1-1.
Setting of model selection".
2. Selecting and carrying out service menu

1) Select the optional selection function
(OPTIONAL SELECTION) in the service
menu selection screen by referring to "1-1.
Setting of model selection".
6 HD465-7R, HD605-7R
2) After selecting the optional selection func- a Perform after checking that the model has
tion, press [U] switch for longer than 5 been set.
seconds and display the setting screen for a Always check all the items.
the optional item selection. a Settle the first item by pressing the [U] switch
q [U]: Conduct the service menu. twice, even if the current setting is correct (to
a Press [U] switch for longer than 5 transmit the information to the other control-
seconds, otherwise it will not change lers).
to optional item selection screen. a After setting, be sure to turn the starting switch
a The setting status of that optional OFF and wait for 15 seconds to settle the
item is displayed at the left of the memory of each controller.
lower row.
q ADD: Option is set. 3. Setting of ARSC (02: ARSC)
q NO ADD: Option is not set. 1) While the optional item selection screen is
displayed, select ARSC (02: ARSC).
a The current setting condition is dis-
played on the left side of the lower
line.
q ADD: ARSC is set.
q NO ADD: ARSC is not set.

in the option item selection screen, the
optional item is displayed endlessly in the
order shown in the below table, so select
the necessary item.
a Be sure to start setting of optional
functions from code No. 02. 2) Check the installation condition of ARSC
q [>]: To proceed to next option item. and setting condition on the screen and
q [>]: To return to previous option item. press the [U] switch to settle the setting.
a Displayed option items: q [U]: Change setting (Display chang-
Display Check item
es).
q [t]: Return to optional item selection
02: ARSC ARSC screen.
03: ASR ASR q ADD: Set option.
04: ABS ABS q NO ADD: Set no option.
05: AUTO SUS Auto-suspension
a If the setting is settled with the [U]
switch, it is effective even after this
07: VHMS/PLM VHMS/PLM screen is turned OFF.
09: — —
10: — —
11: — —
12: TIRE SIZE Tire size compensation
13: INCLINOMET. Inclinometer
14: F BRAKE CUT Front brake cut
Speed unit selection
15: SPEED (UNIT)
(Do not change, basically)
16: — —
19: SENSOR Maintenance sensor
HD465-7R, HD605-7R 7
4. Setting of ASR (03: ASR) 5. Setting of ABS (04: ABS)

1) While the optional item selection screen is 1) While the optional item selection screen is
displayed, select ASR (03: ASR). displayed, select ABS (04: ABS).
a The current setting condition is dis- a The current setting condition is dis-
played on the left side of the lower played on the left side of the lower
line. line.
q ADD: ASR is set. q ADD: ABS is set.
q NO ADD: ASR is not set. q NO ADD: ABS is not set.
2) Check the installation condition of ASR 2) Check the installation condition of ABS
and setting condition on the screen and and setting condition on the screen and
press the [U] switch to settle the setting. press the [U] switch to settle the setting.
q [U]: Change setting (Display chang- q [U]: Change setting (Display chang-
es). es).
q [ t]: Return to optional item selection q [t ]: Return to optional item selection
screen. screen.
q ADD: Set option. q ADD: Set option.
q NO ADD: Set no option. q NO ADD: Set no option.
a If the setting is settled with the [U] a If the setting is settled with the [U]
switch, it is effective even after this switch, it is effective even after this
screen is turned OFF. screen is turned OFF.
8 HD465-7R, HD605-7R
6. Setting of auto-suspension (05: AUTO SUS) 7. Setting of VHMS/PLM (07: VHMS/PLM)

displayed, select the auto-suspension (05: displayed, select VHMS/PLM (07: VHMS/
AUTO SUS). PLM).
line. line.
q ADD: Auto-suspension is set. q NON: VHMS/PLM is not set.
q NO ADD: Auto-suspension is not set. q VHMS: Only VHMS is set.
q +PLM: VHMS + PLM are set.
2) Check the installation condition of the

auto-suspension and setting condition on 2) Check the installation condition of VHMS/
the screen and press the [U] switch to PLM and setting condition on the screen
settle the setting. and press the [U] switch to settle the set-
q [U]: Change setting (Display chang- ting.
es). q [U]: Change setting (Display chang-
q [ t]: Return to optional item selection es).
screen. q [t ]: Return to optional item selection
q ADD: Set option. screen.
q NO ADD: Set no option. q NON: Set no option.
a If the setting is settled with the [U] q VHMS: Set VHMS.
switch, it is effective even after this q +PLM: Set VHMS + PLM.
screen is turned OFF. a If the setting is settled with the [U]
switch, it is effective even after this
screen is turned OFF.
HD465-7R, HD605-7R 9
8. Setting of tire size compensation (12: TIRE 9. Setting of inclinometer (13: INCLINOMET.)
SIZE) 1) While the optional item selection screen is
1) Select the tire size compensation (12: displayed, select the inclinometer (13:
TIRE SIZE) in the option item selection INCLINOMET.).
screen. a The current setting condition is dis-
a The present compensation value is played on the left side of the lower
displayed at the left of the lower row. line.
***%: Rate of change from standard q ADD: Inclinometer is set.
tire q NO ADD: Inclinometer is not set.
2) For changing the compensation value, 2) Check the installation condition of the
press the [U] switch to display the com- inclinometer and setting condition on the
pensation value input screen. screen and press the [U] switch to settle
q [U]: To change compensation value. the setting.
3) After displaying the compensation value q [U]: Change setting
input screen, operate each of the switches (Display changes).
[>], [<], [U] and [t] to input the compen- q [t ]: Return to optional item selection
sation value directly. screen.
q [ > ]: To switch the cursor symbol (+/-); q ADD: Set option.
To increase number. q NO ADD: Set no option.
q [ < ] :To switch the cursor symbol (+/-); a If the setting is settled with the [U]
To decrease number. switch, it is effective even after this
q [U]: To determine compensation val- screen is turned OFF.
ue.
q [ t]: Cursor moves to left end / To re-
turn to optional item selection
screen.
a The compensation value at the plant
before shipment is [+/- 00%] (In case
of inputting 00, +/- does not matter.)
a The compensation value can be input
within the range of [-10 % – +10 %].
10 HD465-7R, HD605-7R
10. Setting of front brake cut (14: F BRAKE CUT.) 11. Setting of maintenance sensor (19: SENSOR.)
displayed, select the front brake cut (14: F displayed, select themaintenance sensor
BRAKE CUT.). (19: SENSOR.).
line. line.
q ADD: Front brake cut is set. q ADD: Maintenance sensor is set.
q NO ADD: Front brake cut is not set. q NO ADD: Maintenance sensor is not
set.
2) Check the installation condition of the front

brake cut function and setting condition on 2) Check the installation condition of the mai-
the screen and press the [U] switch to tenance sensor function and setting condi-
settle the setting. tion on the screen and press the [U]
q [U]: Change setting switch to settle the setting.
(Display changes). q [U]: Change setting
q [ t]: Return to optional item selection (Display changes).
screen. q [t ]: Return to optional item selection
q ADD: Set option. screen.
q NO ADD: Set no option. q ADD: Set option.
a If the setting is settled with the [U] q NO ADD: Set no option.
switch, it is effective even after this a If the setting is settled with the [U]
screen is turned OFF. switch, it is effective even after this
screen is turned OFF.
HD465-7R, HD605-7R 11
12. Storing data in controller 1-3. OFF setting of maintenance monitor (corro-
1) Check that the setting for all items has sion resistor)
been completed in the sub menu screen 1. Switching to service mode
for the optional item selection function. Switch to the service mode by referring to "1-1.
2) Turn the starting switch OFF and keep Setting of model selection".
that condition for longer than 15 seconds.
a Unless the starting switch is turned off 2. Selecting and carrying out service menu
for longer than 15 seconds, the new 1) Select the filter and oil replacement time
data is not memorized in the controller. setting function (MAINTENANCE MONI-
3) Turn the starting switch ON again. TO R) in the service menu selection
a After this operation the option setting screen referring to "1-1. Setting of model
becomes effective. selection".
3. Displaying and selecting of maintenance item

1) While the filter and oil replacement time
setting function is selected, display the
maintenance item selection screen by
pressing the [U] switch.

in the maintenance item selection screen,
the maintenance item is displayed end-
lessly in the order shown in the below
table, so select the corrosion register (06:
CORR RES).
q [>]: To proceed to next maintenance
item.
q [<]: To return to previous mainte-
nance item.
12 HD465-7R, HD605-7R
a Displayed maintenance items: 2) After displaying the interval change

screen, press the [>] or [<] switch further
Display Maintenance items and functions
and display the setting screen for validity
41:FUEL P FILT Fuel pre filter or invalidity.
01:ENG OIL Engine oil q [>]: Change the displayed screen
02:ENG FILT Engine oil filter q [<]: Change the displayed screen
13:TM FILT Transmission oil filter a If the present setting is ON, the
03:FUEL FILT Fuel main filter
screen displays as above, and if the
present setting is OFF, it displays as
06:CORR RES Corrosion resistor
below.
24: Torque convertor/Transmission/ a The default setting of the machine
TC/TM/BK OIL Brake oil monitor is ON (above).
14:BK OIL FILT Brake oil filter a If the present setting is ON (above),
16:BK C FILT Brake cooling oil filter carry out the further operation to
04:HYD FILT Hydraulic oil filter change the setting to OFF.
11:DIFF OIL Differential oil a If the present setting is OFF (below),
press the [t] switch to complete the
08:FNL OIL Final drive oil
setting.
10:HYD OIL Hydraulic oil
INTIALIZE Setting default value for all items
ALL ITEMS Setting validity or invalidity for all items
a As for the use of maintenance items

besides the corrosion register, refer to
t he se cti on " Sp ec ial f unc ti on of
machine monitor".
3) In order to change the present setting

from ON to OFF, press the [U] switch to
display the setting change screen.
q [U]: Change setting.
4) After displaying the setting change
screen, operate [>], [<], and [t] switch to
determine OFF setting.
q [<]: Select YES (move cursor)
q [>]: Select NO (move cursor)
4. OFF setting of corrosion register item
q [t]: To determine selection.
1) With the corrosion register selected, press
the [U] switch and display the interval
change screen.
q [U]: To carry out interval change.
HD465-7R, HD605-7R 13
Special functions of machine monitor (EMMS) 1

a 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
internal 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 inspec-
tion, maintenance, and troubleshooting.
14 HD465-7R, HD605-7R
Operator mode io Service mode

1 Service meter, odometer display function (default) (*1) 10 Electric system fault history display function
2 Dump counter display function (when option is selected) 11 Mechanical system fault history display function
3 Reverse travel distance display function 12 Real-time monitoring function
4 Filter replacement, oil change interval display function 13 Cylinder cut-out mode
5 Telephone number input function 14 No-injection cranking function
6 Language selection function 15 Adjustment function
7 PLM setup function 16 Filter replacement, oil change interval display function
8 Action code display function 17 Operation information display function
9 Failure code display function 18 Engine mode fixing function
*1: PLM (payload meter) display function when 19 Manual snapshot function
receiving VHMS data 20 PLM setting function (when option is selected)
21 Option selection function

22 Model selection function
23 Initialize function (factory use only)
HD465-7R, HD605-7R 15
Function and flow of each mode
*1: Applicable only when VHMS is installed.

*2: Applicable only when PLM built in VHMS is installed.
16 HD465-7R, HD605-7R
Operator mode Character display portion

16 characters can be displayed on each upper and
a No. 2 – No. 7 is displayed endlessly by follow-
lower row of the character display section, and
ing the switch operation.
depending on the contents displays the combina-
a When a failure occurs, the screen changes
tion of the next figures, letters, and symbols.
automatically to No. 8 regardless of the dis-
1) Arabic numbers: 1, 2, 3, . . .
played screen.
2) Small letters: a, b, c, . . .
a If the switch is not operated for over 30 sec-
3) Capital letters: A, B, C, . . .
onds regardless of the display screen, the
4) Katakana: A, I, U, . . . (Only for Japanese dis-
screen automatically;
play)
q Changes to No. 1.
5) Symbols: @, ?, $, . . .
(If malfunction has not occurred.)
6) Special letters:
q Changes to No. 8.
(If malfunction has occurred.)
a After moving from No. 9 to No. 1 by the switch
operation, if no switch operation is performed
for longer than 10 seconds, then it automati-
cally moves to No. 8.
Service mode
a No. 10 – No. 23 is displayed endlessly by fol-
lowing the switch operation.
a By inputting and determining the ID once, it will
be effective until the starting switch is turned
off.
Control switch section

All the display operation of the machine monitor is
operated by the machine monitor mode selector
switches (1) and (2).
Each switch of [U], [t], [>], [<] is assigned to the
following function.
1) U: Determine and execute
2) t : To cancel, release, and determine
(only YES and NO screen)
3) > : To right, to next, to proceed, to increase
(only when inputting Arabic numbers)
4) < : To left, to previous, to return, to decrease
(only when inputting Arabic numbers)
HD465-7R, HD605-7R 17
t Operator mode (Outline) [3] Integrated reverse travel odometer display

function
[1] Service meter and engine speed display Machine monitor displays the integrated reverse
function travel odometer by operating the switch.
When turning the starting switch ON, the service a For details, see operation manual.
meter and integrated odometer are displayed in the
upper and lower row respectively.
a For details, see operation manual.
[4] Filter and oil replacement time display

function
1. Replacement time display of filter and oil (dis-
[2] Dump counter display function played automatically)
(When option is selected) When the replacement interval for the various
Display the dump counter by operating the machine filters or oils approaches, the machine monitor
monitor switch. automatically displays the information to
a Dump counter is displayed only when the op- remind an operator of maintenance.
tion selection is set to be effective in the ser-
vice mode.
18 HD465-7R, HD605-7R
2. Reset of replacement time (selection menu) [6] Language selection function

The machine monitor can reset the interval Display language of the machine monitor can be
time by operating the switch, if various filters selected with the switch operation.
and oils maintenances are finished. a The Service mode function is not included in
a For details, see operation manual. the display selection function, therefore always
a Replacement interval time setting can be displayed in English.
operated by the filter and oil replacement a For details, see operation manual.
time setting function in the service mode.
[7] PLM setting function (when option is se-

[5] Phone No. input function lected)
Phone No. set in the machine monitor can be input- This function sets and displays the payload meter.
ted, corrected, and released by the switch opera- a For details, see Operation and Maintenance
tion. Manual.
a Phone No. is displayed together with "CALL"
when action code "E03" is displayed.
HD465-7R, HD605-7R 19
[8] Action code display function [9] Failure code display function
When abnormal situations occur, the machine mon- By pressing the [>] switch once while the action
itor automatically displays the action code depend- code is displayed on the machine monitor, the
ing on the extent of the abnormality in order to present failure code is displayed.
remind the operator of proper remedy. q [>]: To display failure code.
a Below figure shows the example of displaying
action code "E03" and "CALL + phone No."
alternately.
a "CALL + phone No." is not displayed if the
action code "E01" or "E02" is displayed.
a The failure codes which have been detected in

the past are separated into electrical and
mechanical systems and recorded as failure
history (refer to service mode for a detail).
a If there are several failures, other failure codes
a Action code and remedy requested for an op- are displayed by pressing the [>] switch.
erator a After displaying all the failure codes by press-
ing the [>] switch, press [>] switch further to
Action CALL +
Remedy requested for operator return to the service meter and integrated
code phone No.
odometer display screen.
• Carry out test and maintenance Press the [>] switch again, and the failure code
E01 None when operation is finished or is displayed from the beginning.
operator is changed. a If there is no switch operation for longer than
• If related to an over run is dis- 10 seconds in the service meter and integrated
played:Travel keeping the engine odometer display screen, it automatically
speed and machine speed down. switches to the action code display screen.
E02 None • If related to an overheat is dis- a The following information is displayed in the
played:Stop machine and keep service code display function.
engine with no-load medium A: Failure code (4-digits device code + 2-digits
speed running. symptom code)
• Stop the engine and machine B: Controller code
E03 Yes immediately and contact the ser- MON: Machine monitor
vice personnel. ENG: Engine controller
TM: Transmission controller
BK: Retarder controller
PLM: PLM function system of VHMS
controller (when option is selected)
ABS: ABS controller
(when option is selected)
C: Trouble occurring system
20 HD465-7R, HD605-7R
a Refer to "Failure code table" for details of dis-

played failure codes.
a Be careful of the partial difference in the dis-
played information for the failure code display
function and the failure history display function
(service mode).
HD465-7R, HD605-7R 21
Failure code table

Failure Applicable Action History
Failure contents
codes equipment code classification
1500L0 Detection of double engagement TM E03 Mechanical system
15B0NX Clogging of transmission oil filter TM E01 Mechanical system
15F0KM Abuse 1 of gear shifting from reverse to forward TM — Mechanical system
15F0MB Abuse 2 of gear shifting from reverse to forward TM — Mechanical system
15F7KM Abuse of transmission forward clutch disk TM — Mechanical system
Trouble in reverse clutch system
15G0MW TM E03 Electrical system
(command holding pressure, fill ON, detection of slip)
15G7KM Abuse of transmission reverse clutch disk TM — Mechanical system
Trouble in high clutch system
15H0MW TM E03 Electrical system
Trouble in low clutch system
15J0MW TM E03 Electrical system
Trouble in 1st clutch system
15K0MW TM E03 Electrical system
Trouble in 2nd clutch system
15L0MW TM E03 Electrical system
Trouble in 3rd clutch system
15M0MW TM E03 Electrical system
Trouble in 4th clutch system
15N0MW TM E03 Electrical system
Trouble I in reverse clutch pressure control valve
15SBL1 TM E03 Electrical system
(command OFF, fill ON)
Trouble II in reverse clutch pressure control valve
15SBMA TM E03 Electrical system
(command holding pressure, fill OFF, detection of slip)
Trouble I in high clutch pressure control valve
15SCL1 TM E03 Electrical system
Trouble II in high clutch pressure control valve
15SCMA TM E03 Electrical system
Trouble I in low clutch pressure control valve
15SDL1 TM E03 Electrical system
Trouble II in low clutch pressure control valve
15SDMA TM E03 Electrical system
Trouble I in 1st clutch pressure control valve
15SEL1 TM E03 Electrical system
Trouble II in 1st clutch pressure control valve
15SEMA TM E03 Electrical system
Trouble I in 2nd clutch pressure control valve
15SFL1 TM E03 Electrical system
Trouble II in 2nd clutch pressure control valve
15SFMA TM E03 Electrical system
Trouble I in 3rd clutch pressure control valve
15SGL1 TM E03 Electrical system
Trouble II in 3rd clutch pressure control valve
15SGMA TM E03 Electrical system
Trouble I in 4th clutch pressure control valve
15SHL1 TM E03 Electrical system
Trouble II in 4th clutch pressure control valve
15SHMA TM E03 Electrical system
Trouble II in lockup clutch pressure control valve
15SJMA TM E03 Electrical system
(command holding pressure, detection of slip)
22 HD465-7R, HD605-7R

Failure contents
2C4MNX Clogging of retarder cooling oil filter BK E01 Electrical system
2D05CA Wear of brake (rear right) BK E01 Mechanical system
2D06CA Wear of brake (rear left) BK E01 Mechanical system
2F00KM Dragging of parking brake TM — Mechanical system
2G42ZG Lowering of accumulator oil pressure (front) TM E03 Mechanical system
2G43ZG Lowering of accumulator oil pressure (rear) TM E03 Mechanical system
6014NX Clogging of hydraulic oil filter BK E01 Mechanical system
Operation of engine overrun prevention device
989A00 (Note: Information is obtained from transmission controller MON E02 Mechanical system
and failure code is displayed on monitor panel)
Inclination alarm (Raising body while machine is inclined)
989D00 (Note: Information is obtained from transmission controller MON — Mechanical system
and failure code is displayed on monitor panel)
A570NX Clogging of engine oil filter BK E01 Mechanical system
AA10NX Clogging of air cleaner TM E01 Mechanical system
AB00MA Trouble in battery charge circuit (No R-terminal signal) TM E03 Electrical system
B@BAZG Lowering of engine oil pressure ENG E03 Mechanical system
B@BAZK Lowering of engine oil level BK E01 Mechanical system
B@BCNS Overheating of engine ENG E02 Mechanical system
B@BCZK Low coolant level alarm TM E01 Mechanical system
B@C7NS Overheating of brake cooling oil (rear) MON E02 Mechanical system
B@CENS Overheating of torque converter oil MON E02 Mechanical system
B@GAZK Lowering of battery electrolyte level BK E01 Mechanical system
B@HAZK Lowering hydraulic oil level BK E01 Mechanical system
B@JANS Overheating of steering oil TM E02 Mechanical system
CA111 Abnormality in engine controller ENG E03 Electrical system
CA115 Abnormality in engine Ne/Bkup speed sensor ENG E03 Electrical system
CA122 Abnormally high level of charge pressure sensor ENG E03 Electrical system
CA123 Abnormally low level of charge pressure sensor ENG E03 Electrical system
CA131 Abnormally high level of throttle sensor ENG E03 Electrical system
CA132 Abnormally low level of throttle sensor ENG E03 Electrical system
CA135 Abnormally high level of oil pressure sensor ENG E01 Electrical system
CA141 Abnormally low level of oil pressure sensor ENG E01 Electrical system
CA144 Abnormally high level of coolant temperature sensor ENG E01 Electrical system
CA145 Abnormally low level of coolant temperature sensor ENG E01 Electrical system
CA153 Abnormally high level of charge temperature sensor ENG E01 Electrical system
CA154 Abnormally low level of charge temperature sensor ENG E01 Electrical system
CA187 Abnormally low level of sensor power supply 2 ENG E03 Electrical system
Abnormally high level of engine oil temperature sensor
CA212 ENG E01 Electrical system
(for VHMS)
Abnormally low level of engine oil temperature sensor
CA213 ENG E01 Electrical system
(for VHMS)
CA221 Abnormally high level of ambient air pressure sensor ENG E01 Electrical system
CA222 Abnormally low level of ambient air pressure sensor ENG E01 Electrical system
CA227 Abnormally high level of sensor power supply 2 ENG E03 Electrical system
HD465-7R, HD605-7R 23

Failure contents
CA234 Overspeed of engine ENG E02 Mechanical system
CA238 Abnormality in Ne speed sensor power supply ENG E03 Electrical system
CA263 Abnormally high level of fuel temperature sensor ENG E01 Electrical system
CA265 Abnormally low level of fuel temperature sensor ENG E01 Electrical system
CA271 Short circuit in PCV1 ENG E03 Electrical system
CA272 Disconnection in PCV1 ENG E03 Electrical system
CA273 Short circuit in PCV2 ENG E03 Electrical system
CA274 Disconnection in PCV2 ENG E03 Electrical system
CA322 Disconnection or short circuit in injector #1 system ENG E03 Electrical system
CA342 Abnormality in matching of engine controller data ENG E03 Electrical system
CA351 Abnormality in injector drive circuit ENG E03 Electrical system
CA352 Abnormally low level of sensor power supply 1 ENG E03 Electrical system
CA386 Abnormally high level of sensor power supply 1 ENG E03 Electrical system
CA431 Abnormality in idle validation switch ENG E01 Electrical system
CA432 Abnormality in idle validation setting ENG E03 Electrical system
CA441 Abnormally low level of source voltage ENG E03 Electrical system
CA442 Abnormally high level of source voltage ENG E03 Electrical system
CA449 Abnormality 2 in common rail high pressure ENG E03 Electrical system
CA451 Abnormally high level of common rail pressure sensor ENG E03 Electrical system
CA452 Abnormally low level of common rail pressure sensor ENG E03 Electrical system
CA553 Abnormality 1 in common rail high pressure ENG E03 Electrical system
CA554 In-range trouble of common rail pressure sensor ENG E03 Electrical system
CA559 Lowering 1 of supply pump pressure ENG E03 Electrical system
CA689 Abnormality in engine Ne speed sensor ENG E03 Electrical system
CA731 Abnormality in engine Bkup speed sensor phase ENG E03 Electrical system
CA757 Loss of all engine controller data ENG E03 Electrical system
CA778 Abnormality in engine Bkup speed sensor ENG E03 Electrical system
CA1633 Abnormality in KOMNET ENG E03 Electrical system
CA2185 Abnormally high level of throttle sensor power supply ENG E03 Electrical system
CA2186 Abnormally low level of throttle sensor power supply ENG E03 Electrical system
CA2249 Lowering 2 of supply pump pressure ENG E03 Electrical system
CA2555 Abnormally low level of intake air heater relay voltage ENG E01 Electrical system
CA2556 Abnormally high level of intake air heater relay voltage ENG E01 Electrical system
D19HKB Trouble in stop lamp relay output system BK E01 Electrical system
D5ZKKZ Trouble in front brake cut valve system BK E01 Electrical system
DAF9KM Wrong connection of connector MON E03 Electrical system
(DAFRKR) Abnormality in CAN communication (monitor panel) TM — —
DAQ0KK Lowering of source voltage TM E03 Electrical system
24 HD465-7R, HD605-7R

Failure contents
DAQ0KT Abnormality in non-volatile memory TM E01 Electrical system
DAQ2KK Trouble in solenoid power supply system TM E03 Electrical system
Disagreement of model selection signals
(DAQ9KQ) MON E03 —
(transmission controller)
Abnormality in CAN communication
DAQRKR MON E03 Electrical system
(transmission controller)
(DAQRMA) Disagreement of option setting (transmission) MON E03 —
DB10KT Abnormality in non-volatile memory BK E01 Electrical system
DB12KK Trouble in solenoid power supply BK E03 Electrical system
DB13KK Lowering of battery direct power supply voltage BK E03 Electrical system
(DB19KQ) Disagreement of model selection signals (brake) MON E03 —
DB1RKR Abnormality in CAN communication (retarder controller) TM E03 Electrical system
(DB1RMA) Disagreement of option setting (brake) MON E03 —
DB2RKR Abnormality in CAN communication (engine controller) TM E03 Electrical system
DBBRKR Abnormality in CAN communication (VHMS) MON E01 Electrical system
DBC2KK Trouble in solenoid power supply system ABS E03 Electrical system
DBC3KK Lowering of battery direct power supply voltage ABS E03 Electrical system
(DBC9KQ) Disagreement of model selection signals (ABS) MON E03 —
DBCRKR Abnormality in CAN communication (ABS) TM E03 Electrical system
(DBCRMA) Disagreement of option setting (ABS) MON E03 —
DDD7KX Trouble in travel speed setting switch system BK E03 Electrical system
DDD8KA Disconnection in ARSC system switch BK E03 Electrical system
DDD8KB Short circuit in ARSC system switch BK E03 Electrical system
DDD9KA Disconnection in ABS system switch ABS E03 Electrical system
DDD9KB Short circuit in ABS system switch ABS E03 Electrical system
DDDAKA Disconnection in ASR system switch BK E01 Electrical system
DDDAKB Short circuit in ASR system switch BK E01 Electrical system
DDP6L4 Trouble in service brake pressure switch ABS E03 Electrical system
Trouble in high clutch flow sensor valve
DDTHKA TM E03 Electrical system
(command holding pressure, fill OFF, no slip)
Trouble in low clutch flow sensor valve
DDTJKA TM E03 Electrical system
Trouble in 1st clutch flow sensor valve
DDTKKA TM E03 Electrical system
Trouble in 2nd clutch flow sensor valve
DDTLKA TM E03 Electrical system
Trouble in 3rd clutch flow sensor valve
DDTMKA TM E03 Electrical system
Trouble in reverse clutch flow sensor valve
DDTNKA TM E03 Electrical system
Trouble in 4th clutch flow sensor valve
DDTPKA TM E03 Electrical system
DF10KA Input of no lever signal TM E03 Electrical system
DF10KB Input of multiple lever signal TM E03 Electrical system
Transmission oil temperature sensor input signal out of
DGF1KX TM E03 Electrical system
range
HD465-7R, HD605-7R 25

Failure contents
Trouble in retarder oil temperature sensor (rear wheel)
DGR2KZ BK E01 Electrical system
system (ground fault)
DGR6KX Steering oil temperature signal out of range TM E01 Electrical system
Torque converter oil temperature sensor input signal out of
DGT1KX TM E01 Electrical system
range
Short circuit in suspension pressure sensor system VHMS
DHP4KY E01 Electrical system
(front right) (indication: PLM)
Disconnection or ground fault in suspension pressure VHMS
DHP4KZ E01 Electrical system
sensor system (front right) (indication: PLM)
(front left) (indication: PLM)
sensor system (front left) (indication: PLM)
DHP6KA Trouble in suspension pressure sensor system (rear right) BK E01 Electrical system
DHP6KX Trouble in suspension pressure sensor system (rear right) BK E03 Electrical system
(rear right) (indication: PLM)
sensor system (rear right) (indication: PLM)
DHP7KA Trouble in suspension pressure sensor system (rear left) BK E01 Electrical system
DHP7KX Trouble in suspension pressure sensor system (rear left) BK E03 Electrical system
(rear left) (indication: PLM)
sensor system (rear left) (indication: PLM)
Disconnection, ground fault or hot short in torque converter
DHT5KX TM E01 Electrical system
inlet oil pressure sensor
DHT5L6 Trouble in torque converter inlet oil pressure sensor TM E01 Electrical system
DHU2KX Trouble in accumulator oil pressure sensor (front) TM E01 Electrical system
DHU3KX Trouble in accumulator oil pressure sensor (rear) TM E01 Electrical system
DHU6KX Trouble in ABS control valve pressure sensor (front right) ABS E03 Electrical system
DHU7KX Trouble in ABS control valve pressure sensor (front left) ABS E03 Electrical system
DHU8KX Trouble in ABS control valve pressure sensor (rear right) ABS E03 Electrical system
DHU9KX Trouble in ABS control valve pressure sensor (rear left) ABS E03 Electrical system
DJF1KA Disconnection in fuel level sensor system TM E01 Electrical system
DK30KX Trouble in steering angle potentiometer BK E01 Electrical system
DK51L5 Trouble in manual retarder potentiometer and RVS BK E03 Electrical system
DK52KX Trouble 1 in hoist lever potentiometer sensor BK E03 Electrical system
DK53L8 Trouble 2 in hoist lever potentiometer sensor BK E03 Electrical system
DK54KX Trouble in boom positioner sensor BK E03 Electrical system
DKD0L6 Trouble in steering speed sensor BK E01 Electrical system
DKH0KX Inclinometer sensor signal out of range TM E01 Electrical system
VHMS
DKH1KX Abnormality in inclinometer E01 Electrical system
(indication: PLM)
Disconnection in transmission input shaft speed sensor
DLF1KA TM E03 Electrical system
system
DLF1LC Trouble in transmission input shaft speed sensor TM E03 Electrical system
26 HD465-7R, HD605-7R

Failure contents
Disconnection in transmission intermediate shaft speed
DLF2KA TM E03 Electrical system
sensor system
DLF2LC Trouble in transmission intermediate shaft speed sensor TM E03 Electrical system
DLF6KA Disconnection in wheel speed sensor (front right) ABS E03 Electrical system
DLF6L3 Trouble in wheel speed sensor (front right) ABS E03 Electrical system
DLF7KA Disconnection in wheel speed sensor (front left) ABS E03 Electrical system
DLF7L3 Trouble in wheel speed sensor (front left) ABS E03 Electrical system
DLF8KA Disconnection in wheel speed sensor (rear right) BK E01 Electrical system
DLF8L3 Trouble in wheel speed sensor (rear right) ABS E03 Electrical system
DLF8LC Trouble in wheel speed sensor system (rear right) BK E01 Electrical system
DLF8MA Disconnection in wheel speed sensor (rear right) ABS E03 Electrical system
DLF9KA Disconnection in wheel speed sensor (rear left) BK E01 Electrical system
DLF9L3 Trouble in wheel speed sensor (rear left) ABS E03 Electrical system
DLF9LC Trouble in wheel speed sensor system (rear left) BK E01 Electrical system
DLF9MA Disconnection in wheel speed sensor (rear left) ABS E03 Electrical system
Disconnection in transmission output shaft speed sensor
DLT3KA TM E03 Electrical system
system
DLT3LC Trouble in transmission output shaft sensor BK E01 Electrical system
DLT4KA Disconnection in transmission output shaft speed sensor BK E01 Electrical system
DLT4MA Disconnection in transmission output shaft speed sensor BK E03 Electrical system
DV00KB Short circuit in buzzer output MON E01 Electrical system
DW2AKA Disconnection in main pressure variable valve output TM E01 Electrical system
DW2AKB Ground fault in main pressure variable valve output circuit TM E01 Electrical system
DW2AKY Hot short in main pressure variable valve output circuit TM E01 Electrical system
DW2AL1 Defective reset of main pressure variable valve TM E01 Electrical system
DW2ALH Malfunction of main pressure variable valve TM E01 Electrical system
Trouble in auto-suspension solenoid 1 output system
DW35KZ BK E01 Electrical system
(disconnection or ground fault)
Trouble in auto-suspension solenoid 2 output system
Trouble in kick-out solenoid output system
Trouble (disconnection or ground fault) in hoist selector
valve output system (disconnection or ground fault)
DW78KZ Trouble in BCV output system BK E01 Electrical system
DWNBK4 Trouble in ASR shut-off valve (valve keeps operating) BK E01 Electrical system
DWNBKA Disconnection in ASR shut-off valve output circuit BK E01 Electrical system
DWNBKB Ground fault in ASR shut-off valve output circuit BK E01 Electrical system
DWNBKY Short circuit in ASR shut-off valve output circuit BK E01 Electrical system
DWNBMA Trouble in ASR shut-off valve (valve does not operate) BK E01 Electrical system
DWNDKZ Trouble in ABS cut valve (front) system ABS E03 Electrical system
DWNDMA Defective ABS cut valve (front) ABS E03 Electrical system
DWNEKZ Trouble in ABS cut valve (rear) system ABS E03 Electrical system
DWNEMA Defective ABS cut valve (rear) ABS E03 Electrical system
Trouble in rear wheel proportional pressure reducing
DX11K4 BK E03 Electrical system
solenoid valve (valve keeps operating)
HD465-7R, HD605-7R 27

Failure contents
Disconnection in rear wheel proportional pressure reducing
DX11KA BK E03 Electrical system
solenoid valve output circuit
Ground fault in rear wheel proportional pressure reducing
DX11KB BK E03 Electrical system
Short circuit in rear wheel proportional pressure reducing
DX11KY BK E03 Electrical system
Trouble in rear wheel proportional pressure reducing
DX11MA BK E03 Electrical system
solenoid valve (valve does not operate)
DX13KA Disconnection in hoist EPC valve output circuit BK E03 Electrical system
DX13KB Ground fault in hoist EPC valve output circuit BK E03 Electrical system
DX13KY Short circuit in hoist EPC valve output circuit BK E03 Electrical system
Trouble in ASR proportional pressure reducing solenoid
valve (right) (valve keeps operating)
Disconnection in ASR proportional pressure reducing
solenoid valve (right) output circuit
Ground fault in ASR proportional pressure reducing
Short circuit in ASR proportional pressure reducing
valve (right) (valve does not operate)
valve (left) (valve keeps operating)
Disconnection in ASR proportional pressure reducing
solenoid valve (left) output circuit
Ground fault in ASR proportional pressure reducing
Short circuit in ASR proportional pressure reducing
valve (left) (valve does not operate)
Disconnection in ABS control valve (front right) output
DX21KA ABS E03 Electrical system
circuit
DX21KB Ground fault in ABS control valve (front right) output circuit ABS E03 Electrical system
DX21KY Short circuit in ABS control valve (front right) output circuit ABS E03 Electrical system
DX21MA Defective ABS control valve (front right) ABS E03 Electrical system
DX22KA Disconnection in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22KB Ground fault in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22KY Short circuit in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22MA Defective ABS control valve (front left) ABS E03 Electrical system
Disconnection in ABS control valve (rear right) output
DX23KA ABS E03 Electrical system
circuit
DX23KB Ground fault in ABS control valve (rear right) output circuit ABS E03 Electrical system
DX23KY Short circuit in ABS control valve (rear right) output circuit ABS E03 Electrical system
DX23MA Defective ABS control valve (rear right) ABS E03 Electrical system
DX24KA Disconnection in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24KB Ground fault in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24KY Short circuit in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24MA Defective ABS control valve (rear left) ABS E03 Electrical system
28 HD465-7R, HD605-7R

Failure contents
DX25MA Defective ABS front wheel system control valve ABS E03 Electrical system
DX26MA Defective ABS rear wheel system control valve ABS E03 Electrical system
DXH1KA Disconnection in lockup clutch solenoid output circuit TM E03 Electrical system
DXH1KB Ground fault in lockup solenoid output circuit TM E03 Electrical system
DXH1KY Hot short in lockup clutch solenoid output circuit TM E03 Electrical system
DXH2KA Disconnection in high clutch solenoid output circuit TM E03 Electrical system
DXH2KB Ground fault in high clutch solenoid output circuit TM E03 Electrical system
DXH2KY Hot short in high clutch solenoid output circuit TM E03 Electrical system
DXH3KA Disconnection in low clutch solenoid output circuit TM E03 Electrical system
DXH3KB Ground fault in low clutch solenoid output circuit TM E03 Electrical system
DXH3KY Hot short in low clutch solenoid output circuit TM E03 Electrical system
DXH4KA Disconnection in 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KB Ground fault in 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KY Hot short in 1st clutch solenoid output circuit TM E03 Electrical system
DXH5KA Disconnection in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KB Ground fault in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KY Hot short in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH6KA Disconnection in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KB Ground fault in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KY Hot short in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH7KA Disconnection in reverse clutch solenoid output circuit TM E03 Electrical system
DXH7KB Ground fault in reverse clutch solenoid output circuit TM E03 Electrical system
DXH7KY Hot short in reverse clutch solenoid output circuit TM E03 Electrical system
DXHHKA Disconnection in 4th clutch solenoid output circuit TM E03 Electrical system
DXHHKB Ground fault in 4th clutch solenoid output circuit TM E03 Electrical system
DXHHKY Hot short in 4th clutch solenoid output circuit TM E03 Electrical system
HD465-7R, HD605-7R 29
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
ABS : ABS controller system
VHMS : PLM function system of VHMS controller (Note: Displayed as "PLM" on machine monitor)
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note : Optional equipment is also included in this table.
30 HD465-7R, HD605-7R
t Service mode
Procedure for switching to service mode and
screen display
a When using the service mode, change the
screen by the following special operation.
1. Confirming the screen display

Check that the machine monitor is in operator
mode and the screen is displaying either of the
"service meter and integrated odometer",
"action code", or "failure code".
2. Displaying ID input initial screen

Press the following 2 switches at the same
time for longer than 5 seconds to display the ID 4. Displaying service menu selection screen
input screen. After confirming all 4 digits of ID, display the
q [t] switch and [<] switch service menu selection screen in the service
a If the switch is pressed for longer than 5 mode.
seconds, the character display section a By inputting and determining the ID once,
becomes blank. After confirming this con- it will be effective until the starting switch
dition, release the switch. is turned off.
3. Input and determination of ID 5. Selection of the service menu

After displaying ID input screen, operate [>], If the [>] switch or [<] switch is pressed on the
[<], [U], and [t] switch and input 4 digits ID. service menu selection screen, the service
a ID: 6491 menu is displayed endlessly in the order of the
q [ > ]:Number at the cursor increases. following table, then select the menu that is
q [ < ]:Number at the cursor decreases used.
q [U]: Number at the cursor is determined q [>]: To proceed to next service menu.
q [t ]: Cursor moves to left end or the dis- q [<]: To return to previous service menu.
play returns to operator mode screen.
a If the ID input screen is left without switch
operation for longer than 60 seconds, it
automatically returns to the operator mode
screen.
HD465-7R, HD605-7R 31
a Displayed service menu: a If you return to the operator mode

screen by mistake, repeat the proce-
No. Display Function
dure from step 1 above (however
Electrical system failure history there is no need to input the ID again).
1 ELECTRIC FAULT
display function q When completing all operations:
Mechanical system failure Turn the starting switch OFF.
2 MACHINE FAULT
history display function [10] Electrical system failure history display
REAL-TIME function (ELECTRIC FAULT)
3 Real-time monitoring function The machine monitor retains the data for problems
MONITOR
CYLINDER that occurred in the electrical system in the past as
4 Cylinder cut-out mode function failure history. They can be displayed as follows.
CUT-OUT
1. Selection of the service menu
5 NO INJECTION No injection cranking function
Select electrical system failure history display
6 TUNING Adjusting function function (ELECTRIC FAULT) in the service
MAINTENANCE Filter and oil replacement time menu selection screen.
7
MONITOR setting function a The total number of failure history data
Operation information display items recorded in memory is displayed in
8 OPERATION INFO the [* *] portion.
function
FIX POWER
9 Engine mode fixing function
MODE
10 SNAPSHOT Manual snap shot function
PLM (Payload meter) setting
11 PLM
function
OPTIONAL
12 Option selection function
SELECT
13 MACHINE Model selection function
Initialize function (exclusive
14 INITIALIZE
function for factory)
a The service menu is displayed in the

places marked with [*].
2. Failure history data display
With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
6. Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current function and hierarchy.
q When continuing operations in another
mode or function:
Press the [t] switch and return to the
mode screen to be used or menu screen
to be used.
a Note that if the [t] switch is pressed
on the YES/NO screen, the function
will be executed.
32 HD465-7R, HD605-7R
3. Displayed failure history data 5. Deleting individual failure history data

With the electrical system failure history dis- 1) With the failure history data to be deleted
play function, the following data can be dis- displayed, press the [U] switch and dis-
played. play the individual deletion screen.
1: Record number (recorded up to a maxi- q [U]: Display the deletion screen
mum of 20 items) 2) When the individual deletion screen is dis-
A: Failure code (4-digits device code + 2-dig- played, operate each switch of [<], [>] and
its symptom code) [t].
2: Number of occurrences (number of occur- q [ <]: Select YES (move cursor)
rences of same code in the past) q [ >]: Select NO (move cursor)
3: Elapsed time 1 (time elapsed on service q [t]: Execute YES or NO
meter since first occurrence) a An information which is active cur-
4: Elapsed time 2 (time elapsed on service rently (display is flashing) cannot be
meter since last occurrence) deleted.
a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the failure history display
function and failure code display function
(operator mode) for the electrical system,
the displayed data are partially different.
a If the fault history is not recorded, "-" is
displayed on the display section of 1/A/2/
3/4.
6. Deletion of all the failure history information

1) With the failure history data displayed,
press the [>] switch or [<] switch and dis-
play ALL CLEAR menu screen.
a The ALL CLEAR menu is displayed at
the end of failure history data.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure history data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record 2) When the ALL CLEAR menu is displayed,
number press the [U] switch and display the ALL
CLEAR execution screen.
q [U]: Execute ALL CLEAR menu
HD465-7R, HD605-7R 33
3) When the ALL CLEAR execution screen is [11] Mechanical system failure history display
displayed, operate each switch of [<], [>] function (MACHINE FAULT)
and [t]. The machine monitor retains the data for problems
q [ < ]: Select YES (move cursor) that occurred in the mechanical system in the past
q [ > ]: Select NO (move cursor) as failure history. They can be displayed as fol-
q [t]: Execute YES or NO lows.
a An information which is active cur-
rently (display is flashing) cannot be 1. Selection of the service menu
deleted. Select mechanical system failure history dis-
play function (MACHINE FAULT) in the service
menu selection screen.
a The total number of failure history data
items recorded in memory is displayed in
the [* *] portion.
4) The screen changes to the fault history

screen. Check that the number of records
in ** is "0".
2. Failure history data display

With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
34 HD465-7R, HD605-7R
3. Displayed failure history data

With the mechanical system failure history dis-
play function, the following data can be dis-
played.
1: Record number
A: Failure code (4-digits device code + 2-dig-
its symptom code)
2: Number of occurrences (number of occur-
rences of same code in the past)
3: Elapsed time 1 (time elapsed on service
meter since first occurrence)
4: Elapsed time 2 (time elapsed on service
meter since last occurrence)
a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the failure history display
function and failure code display function
(operator mode) for the mechanical sys-
tem, the displayed data are partially differ-
ent.
a If the fault history is not recorded, "-" is
displayed on the display section of 1/A/2/
3/4.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure history data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record
number
5. Deleting failure history data (not permitted)

a The failure history data for the mechanical
system cannot be deleted.
HD465-7R, HD605-7R 35

© 2007 KOMATSU
All Rights Reserved
36 HD465-7R, HD605-7R
SEN02531-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
HD465-7R, HD605-7R 1
Special functions of machine q [>]: To proceed to next monitoring

system and function
monitor (EMMS) 1 q [<]: Go back to data for previous
[12] Real time monitoring function (REAL-TIME monitoring system and function
MONITOR) a Monitoring system and function to be
The machine monitor can monitor the condition of displayed:
the machine in real time through the signals from
the sensors installed to various parts of the No. Display System and function
machine. 1 MONITOR PANEL Machine monitor system
In the real time monitoring function, the following 2 2 TRANSMISSION Transmission controller system
types of display can be shown. 3 ENGINE Engine controller system
q 1 item independent display (for each controller)
q 2 items simultaneous display (code input) 4 BRAKE Retarder controller system
VHMS controller system
5 VHMS
1. Selection of the service menu (if equipped)
Select real time monitoring function (REAL- ABS controller
6 ABS
TIME MONITOR) in the service menu selec- (if equipped)
tion screen. 2 items simultaneous monitor-
7 2 ITEMS
ing
a Monitoring system and function in dis-

played in the "*" section.
2. Display and selection of monitoring system

and function
1) With the service menu selected, press the
[U] switch to display the monitoring sys-
tem and function selection screen. 3. Setting 1 item individual monitoring
q [U]: Execute the service menu. 1) In the monitoring system and function
selection screen, select the monitoring
system (example: ENGINE) to be used.
2) If the [>] switch or [<] switch is pressed on

the monitoring system and function selec-
tion screen, the monitoring system and
device is displayed endlessly in the follow-
ing order, then select the system or func-
tion that is used.
2 HD465-7R, HD605-7R
2) With the monitoring system selected,

press the [U] switch and display the mon-
itoring display and item selection screen.
q [U]: Implement 1 system individual
monitoring
3) With the monitoring display and item
selection screen displayed, press the [>]
switch or [<] switch and select items to
monitor.
q [>]: To proceed to the next monitoring
item
q [<]: Return to the previous monitoring
item
a The monitored items are scroll-dis-
played due to internal setting. 5. Setting 2 items simultaneous monitoring
a If the switch is kept pressed, the mon- 1) Select 2 items simultaneous monitoring (2
itoring items scroll at high speed. ITEMS) in the monitoring system and
a In the monitoring display and item function selection screen.
selection screen, the information of 2) With 2 items simultaneous monitoring
the monitored items are displayed on selected, press the [U] switch to display
real time. the monitoring code input screen.
q [U]: Implement 2 system individual
monitoring
4) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitoring data display is held
and the [U] mark flashes. If the [U]
switch is pressed again, hold is canceled
and it becomes active again.
q [U]: Hold and release of data display
4. Display data for 1 item individual monitoring

On the 1 item individual monitoring display
screen, the following data are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
a For details, see "Monitoring code table".
HD465-7R, HD605-7R 3
3) In the monitoring code input screen, oper- 6. Display data for 2 items simultaneous monitor-
ate the switches [>], [<], [U] and [t], to ing
input two monitoring codes directly. On the 2 item simultaneous monitoring display
q [ > ]: Number at the cursor increases. screen, the following data are displayed.
q [ < ]: Number at the cursor decreases A : Monitoring code 1
q [U]: Number at the cursor is deter- 1 : Monitoring data 1 (including unit)
mined B : Monitoring code 2
q [ t]: Cursor moves to the left end / To 2 : Monitoring data 2 (including unit)
return to the monitoring system a For details, see "Monitoring code table".
and function selection screen.
4) When both of the monitoring codes have

been confirmed, the screen switches to
the 2 items simultaneous monitoring dis-
play screen.
5) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitor data is held and the
[U] mark flashes.
If the [U] switch is pressed again, hold is
canceled and it becomes active again.
q [U]: Hold and release of data
4 HD465-7R, HD605-7R
Monitoring code table
Monitor panel [machine monitor system]
Monitor-
No. Monitoring item Display of item Display range of data Unit
ing code
********
1 Part No. of software VERSION 20200 (8 digits/numerals and —
symbols)
********
2 Version No. of application VERSION (APP) 20221 (8 digits/numerals and —
symbols)
********
3 Version No. of data VERSION (DATA) 20222 (8 digits/numerals and —
symbols)
4 Rheostat (Night decrease light) RHEOSTAT 30300 0.0 – 51.0 V
0 – F, 0 – F, 0 – F, Display of
5 Rotary switch (SW1 - 3) SW1, SW2, SW3 30800
(SW1, SW2, SW3 from left) condition
ON/OFF, ON/OFF Display of
6 DIP switch (SW5-1, 2) SW5-1, SW5-2 30900
(SW5-1, SW5-2 from left) condition
01010101
10 Input signal (0 - 7) D-IN--0------7 40900 0:OFF/1:ON
(8 digits of 0/1. See detail.)
01010101
11 Input signal (8 - 15) D-IN--8-----15 40901 0:OFF/1:ON
01010101
12 Input signal (16 - 23) D-IN-16-----23 40902 0:OFF/1:ON
01010101
01010101
0101
15 Output signal (0 - 3) D-OUT-0--3 40925 0:OFF/1:ON
HD465-7R, HD605-7R 5
Detailed information of 40900 (D-IN--0------7) Detailed information of 40925 (D-OUT-0--3)

[0] : Dimmer switch (High beam: 1) [0] : Headlamp selection (ON: 1)
[1] : Machine monitor check switch (ON: 1) [1] : Buzzer (Operated: 1)
[2] : AISS LOW switch (ON: 1) [2] : (Unused)
[3] : (Unused) [3] : (Unused)
[4] : (Unused)
[5] : ABS system switch [If equipped]
(Installed: 1)
[6] : Dimmer switch (Passing: 1)
[7] : Power mode switch (Economy mode: 1)
Detailed information of 40901 (D-IN--8-----15)

[8] : Connector check (Always: 1)
[9]: Machine monitor mode switch
([t] is pressed: 1)
[10] : Machine monitor mode switch
([>] is pressed: 1)
([<] is pressed: 1)
[12] : Turn signal lever (Operated to right: 1)
[13] : Turn signal lever (Operated to left: 1)
([U] is pressed: 1)
[15] : (Unused)
Detailed information of 40902 (D-IN--16----23)

[16] : ARSC switch (Upper position: 1)
[17] : ARSC switch (Lower position: 1)
[18] : ABS switch (Upper position: 1)
[19] : ABS switch (Lower position: 1)
[20] : ASR switch (Upper position: 1)
[21] : ASR switch (Lower position: 1)
[22] : Front brake cut switch (ON: 1)
[23] : (Unused)

[24] : Headlamp switch (ON: 1)
[25] : Seat belt switch (Belt is fastened: 1)
[26] : (Unused)
[27] : (Unused)
[28] : (Unused)
[29] : (Unused)
[30] : (Unused)
[31] : (Unused)

[32] : (Unused)
[33] : (Unused)
[34] : Connector check (Always: 1)
[35] : (Unused)
[36] : (Unused)
[37] : (Unused)
[38] : (Unused)
[39] : (Spare for service)
6 HD465-7R, HD605-7R
Transmission [Transmission controller system]
Monitor-
ing code
********
1 Part No. of software VERSION 20201 (8 digits/numerals and —
symbols)
********
symbols)
********
symbols)
0 – 32767
4 Transmission input shaft speed T/M SPEED:IN 31200 rpm
---- [Other than above]
Transmission intermediate shaft 0 – 32767
5 T/M SPEED:MID 31300 rpm
speed ---- [Other than above]
0 – 32767
6 Transmission output shaft speed T/M SPEED:OUT 31400 rpm
0 – 250
7 Fuel level FUEL SENSOR 04201 z
0.00 – 5.00
8 Fuel level FUEL SENSOR 04200 V
9 Alternator R ALTERNATOR R 04301 OFF/ON 0:OFF/1:ON
0 – 160
10 Torque converter oil temperature T/C OIL TEMP 30100 °C
0.00 – 5.00
11 Torque converter oil temperature T/C OIL TEMP 30101 V
0 – 160
12 Transmission oil temperature T/C OIL TEMP 32500 °C
0.00 – 5.00
13 Transmission oil temperature T/C OIL TEMP 32501 V
0 – 160
14 Steering oil temperature STRG OIL TEMP 32701 °C
0.00 – 5.00
15 Steering oil temperature STRG OIL TEMP 32702 V
0.00 – 5.00
16 Torque converter oil pressure T/C OIL PRESS 32600 MPa
0.00 – 5.00
17 Torque converter oil pressure T/C OIL PRESS 32605 V
0.00 – 99.99
18 Accumulator oil pressure (front) ACC OIL PRE F 35500 MPa
0.00 – 99.99
19 Accumulator oil pressure (rear) ACC OIL PRE R 35501 MPa
0.00 – 5.00
20 Accumulator oil pressure (front) ACC OIL PRE F 35504 V
0.00 – 5.00
21 Accumulator oil pressure (rear) ACC OIL PRE R 35505 V
HD465-7R, HD605-7R 7
Monitor-
ing code
0 – 1000
22 Solenoid output (high) ECMV H DIR 31600 mA
0 – 1000
23 Solenoid output (low) ECMV L DIR 31601 mA
0 – 1000
24 Solenoid output (1st) ECMV 1 DIR 31602 mA
0 – 1000
25 Solenoid output (2nd) ECMV 2 DIR 31603 mA
0 – 1000
26 Solenoid output (3rd) ECMV 3 DIR 31604 mA
0 – 1000
27 Solenoid output (4th) ECMV 4 DIR 31605 mA
0 – 1000
28 Solenoid output (R) ECMV R DIR 31606 mA
0 – 1000
29 Solenoid output (lockup) ECMV LU DIR 31609 mA
Transmission main oil pressure 0 – 1000
30 ECMV MAIN P 31643 mA
variable solenoid output ---- [Other than above]
-180.0 – +180.0
31 Pitch angle sensor ANGLE SENSOR 32900 ° [degree]
0.00 – 5.00
32 Pitch angle sensor ANGLE SENSOR 32903 V
0 – 100
33 Brake output (front wheel) BK OUTP DIR F 33807 %
0 – 100
34 Brake output (rear wheel) BK OUTP DIR R 33806 %
-100 – 100
35 Throttle correction value THROTTLE MOD 36000 %
Low clutch trigger correction 00000000 – FFFFFFFF Display of
36 TRIGGER MOD L 38900
quantity (8 digits of 0 – F) condition
High clutch trigger correction 00000000 – FFFFFFFF Display of
37 TRIGGER MOD H 38901
1st clutch trigger correction 00000000 – FFFFFFFF Display of
38 TRIGGER MOD 1 38902
2nd clutch trigger correction 00000000 – FFFFFFFF Display of
3rd clutch trigger correction 00000000 – FFFFFFFF Display of
4th clutch trigger correction 00000000 – FFFFFFFF Display of
R clutch trigger correction 00000000 – FFFFFFFF Display of
42 TRIGGER MOD R 38906
0101010 Recognition of
43 Clutch fill switch FILL HL1234R 38919 (Data is displayed under fill switch
HL1234R) 0:OFF/1:ON
8 HD465-7R, HD605-7R
Monitor-
ing code
0101010 Learning flag
44 Trigger initial learning flag TRIG HL1234R 38920 (Data is displayed under of clutch
HL1234R) 0:OFF/1:ON
0 – 2550
45 Fill time (low) FILL TIME L 41800 ms
0 – 2550
46 Fill time (high) FILL TIME H 41801 ms
0 – 2550
47 Fill time (1st) FILL TIME 1 41802 ms
0 – 2550
48 Fill time (2nd) FILL TIME 2 41803 ms
0 – 2550
49 Fill time (3rd) FILL TIME 3 41804 ms
0 – 2550
50 Fill time (4th) FILL TIME 4 41805 ms
0 – 2550
51 Fill time (R) FILL TIME R 41806 ms
Throttle quantity lower limit value 0.0 – 100.0
52 THROT LIMIT LO 44201 %
output ---- [Other than above]
Throttle quantity upper limit value 0.0 – 100.0
53 THROT LIMIT HI 44200 %
output ---- [Other than above]
01010101
54 Input signal (0 – 7) D-IN--0------7 40905 0:OFF/1:ON
01010101
55 Input signal (8 – 15) D-IN--8-----15 40906 0:OFF/1:ON
01010101
56 Input signal (16 – 23) D-IN-16-----23 40907 0:OFF/1:ON
01010101
0
01010101
59 Output signal (0 – 7) D-OUT-0------7 40949 0:OFF/1:ON
01010101
60 Output signal (8 – 15) D-OUT-8-----15 40950 0:OFF/1:ON
01010101
61 Output signal (16 – 23) D-OUT-16----23 40951 0:OFF/1:ON
HD465-7R, HD605-7R 9
Detailed information of 40905 (D-IN--0------7) Detailed information of 40949 (D-OUT--0------7)

[1] : Transmission filter switch [1] : (Unused)
[3] : Emergency escape switch (ON: 1) [3] : (Unused)
[4] : Starting switch C terminal signal (Start of [4] : (Unused)
engine: 1) [5] : (Unused)
[6] : Emergency steering relay 1 (Driving: 1) [7] : (Unused)
[7] : Gearshift lever (N position: 1)
Detailed information of 40950 (D-OUT--8-----15)
Detailed information of 40906 (D-IN--8-----15) [8] : (Unused)
[8] : Low clutch fill switch (ON: 1) [9] : (Unused)
[9] : 4th clutch fill switch (ON: 1) [10] : (Unused)
[10] : High clutch fill switch (ON: 1) [11] : (Unused)
[11] : 1st clutch fill switch (ON: 1) [12] : (Unused)
[12] : 2nd clutch fill switch (ON: 1) [13] : (Unused)
[13] : 3rd clutch fill switch (ON: 1) [14] : (Unused)
[14] : Reverse clutch fill switch (ON: 1) [15] : (Unused)
[15] : (Unused)
Detailed information of 40951 (D-OUT--16-----23)
Detailed information of 40907 (D-IN--16----23) [16] : (Unused)
[16] : Gearshift lever (R position: 1) [17] : (Unused)
[17] : Gearshift lever (D position: 1) [18] : (Unused)
[18] : Gearshift lever (6 position: 1) [19] : (Unused)
[23] : Gearshift lever (L position: 1)

[24] : (Unused)
[25] : Coolant level
[26] : Air cleaner switch
[27] : Main pressure variable valve pressure switch
[28] : (Unused)
[29] : (Unused)
[30] : (Unused)
[31] : (Unused)

[32] : (Unused)
10 HD465-7R, HD605-7R
Engine [Engine controller system]
Monitor-
ing code
1 Serial No. of hardware ECM S/N 20400 0 – 49999999 —
0.0 – 480.0
2 Battery voltage POWER SUPPLY 03200 V
0 – 4000
3 Engine speed ENG SPEED 01002 rpm
-40 – 210
4 Engine coolant temperature COOLANT TEMP 04104 °C
Engine coolant temperature sen- 0.00 – 5.00
5 COOLANT TEMP 04105 V
sor voltage ---- [Other than above]
-99.9 – 999.9
6 Oil pressure sensor ENG OIL PRESS 37200 kPa
0.00 – 5.00
7 Oil pressure sensor voltage ENG OIL PRESS 37201 V
-40 – 210
8 Engine oil temperature ENG OIL TEMP 42700 °C
Engine oil temperature sensor 0.00 – 5.00
9 ENG OIL TEMP 42702 V
voltage ---- [Other than above]
0 – 400
10 Common rail pressure RAIL PRESS 36400 MPa
Common rail pressure sensor 0.00 – 5.00
11 RAIL PRESS 36402 V
-99.9 – 999.9
12 Atmospheric pressure AMBIENT PRESS 37400 kPa
Atmospheric pressure sensor 0.00 – 5.00
13 AMBIENT PRESS 37402 V
-50 – 200
14 Intake air temperature INTAKE TEMP 18400 °C
Intake air temperature sensor 0.00 – 5.00
15 INTAKE TEMP 18401 V
-40 – 210
16 Fuel temperature FUEL TEMP 04204 °C
0.00 – 5.00
17 Fuel temperature sensor voltage FUEL TEMP 04201 V
-50 – 200
18 Boost temperature CHG TEMP 18500 °C
Boost temperature sensor volt- 0.00 – 5.00
19 CHG TEMP 18501 V
age ---- [Other than above]
-99.9 – 999.9
20 Boost pressure CHG PRESS-A 36500 kPa
0.00 – 5.00
21 Boost pressure sensor voltage CHG PRESS-A 36502 V
-24000 – 24000
22 Engine output torque OUTPUT TORQUE 18700 Nm
0 – 100
23 Converted torque TORQUE RATIO 36700 %
0 – 100
24 Final accelerator position FINAL THROTTLE 31706 %
HD465-7R, HD605-7R 11
Engine [Engine controller system]
Monitor-
ing code
0.0 – 999.9
25 Momentary fuel consumption FUEL RATE 37300 L/h
Final injection rate command 0 – 1000
26 INJECT COMMAND 18600 mg
(by weight) ---- [Other than above]
-180.0 – 180.0
27 Final injection timing command INJECT TIMING 36300 CA
0 – 100
28 Accelerator pedal position THROTTLE POS 31701 %
Accelerator pedal position sen- 0.00 – 5.00
29 THROTTLE POS 31707 V
sor voltage ---- [Other than above]
30 Idling validation signal IVS 1 18300 ON or OFF —
31 Idling validation signal IVS 2 18301 ON or OFF —
-40 – 210
32 Controller inside temperture ECM IN TEMP 18900 °C
Final common rail pressure com- 0 – 400
33 PRESS COMMAND 36200 MPa
mand ---- [Other than above]
PCV valve closing timing (based -180 – 180
34 PCV TIMING 17201 CA
on BTDC) ---- [Other than above]
35 Engine mode selection POWER MODE 17500 0–4 —
Transmitted value is dis-

36 Selected model (left 8 digits) MACHINE ID (H) 00400 —
played (Left 8 of 16 letters)
37 Selected model (right 8 digits) MACHINE ID (L) 00401 —
played (Left 8 of 16 letters)
38 Build version No. BUILD VER 20216 —
played (8 letters)
39 Calibration data version No. CAL VER 20217 —
played (8 letters)
a "CA" in the unit column is an abbreviation for the Crankshaft Angle.
12 HD465-7R, HD605-7R
Brake [Retarder controller system]
Monitor-
ing code
********
1 Version of software VERSION 20214 (8 digits/numerals and —
symbols)
********
symbols)
********
symbols)
0.00 – 5.00
4 ARSC set switch ARSC SET SP SW 37701 V
Transmission output shaft 0 – 32767
5 T/M SPEED:OUT 31403 rpm
speed ---- [Other than above]
0 – 32767
6 Wheel speed (left) WHEEL SPEED L 39705 rpm
0 – 32767
7 Wheel speed (right) WHEEL SPEED R 39704 rpm
Retarder cooling oil tempera-
8 BRAKE OIL T F 30201 (Unused) —
ture (front) [* Unused]
Retarder cooling oil tempera-
9 BRAKE OIL T F 30204 (Unused) —
ture (front) [* Unused]
Retarder cooling oil tempera- 0 – 160
10 BRAKE OIL T R 30211 °C
ture (rear) ---- [Other than above]
Retarder cooling oil tempera- 0.00 – 5.00
11 BRAKE OIL T R 30212 V
ture (rear) ---- [Other than above]
Brake output current (front 0 – 1000
12 BK OUTP DIR F 33700 mA
wheel) ---- [Other than above]
Brake output current (rear 0 – 1000
13 BK OUTP DIR R 33806 mA
wheel) ---- [Other than above]
0.00 – 5.00
14 Retarder lever voltage RETARD LEVER 33900 V
0.00 – 5.00
15 Body positioner BODY POSITION 34602 V
Dump lever (Hoist lever) poten- 0.00 – 5.00
16 DUMP LEVER 1 34304 V
tiometer 1 ---- [Other than above]
Dump lever (Hoist lever) poten- 0.00 – 5.00
17 DUMP LEVER 2 34305 V
tiometer 2 ---- [Other than above]
0 – 1000
18 Hoist EPC output HOIST EPC DIR 45600 mA
Seating control command 0 – 1000
19 S CNT DIR H 45102 mA
(high) ---- [Other than above]
Seating control command 0 – 1000
20 S CNT DIR L 45103 mA
(low) ---- [Other than above]
Seating condition calibration 0.00 – 5.00
21 S CAL A 45201 V
value ( ) ---- [Other than above]
Cylinder stopper calibration 0.00 – 5.00
22 S CAL B 45301 V
value ( ) ---- [Other than above]
0.0 – 10.00
23 Seating control time (high) S CNT TIME H 45402 second
HD465-7R, HD605-7R 13
Brake [Retarder controller system]
Monitor-
ing code
0.0 – 10.00
24 Seating control time (low) S CNT TIME L 45403 second
25 Shut-off valve output SHUT OFF VALVE 45700 0/1 (1 digit of 0/1) 0:OFF/1:ON
-180.0 – +180.0
26 Steering angle sensor STRG ANGLE 35402 ° (degree)
---- [Other than above
0.00 – 5.00
27 Steering angle sensor STRG ANGLE 35400 V
0.0 – 99.99
28 Steering speed STRG ANG SPEED 35403 rad/second
0.00 – 20.10
29 Suspension pressure (left) SUS PRESS (L) 32814 MPa
0.00 – 5.00
30 Suspension pressure (left) SUS PRESS (L) 32815 V
0.00 – 20.10
31 Suspension pressure (right) SUS PRESS (R) 32816 MPa
0.00 – 5.00
32 Suspension pressure (right) SUS PRESS (R) 32817 V
0/1 (1 digit of 0/1) --- [Other
33 Judgment of empty/loaded EMPTY OR LOAD 39400 0:EMPTY/1:LOAD
than above]
0 – 1020
34 ASR output (left) command ASR OUTP DIR L 39601 mA
0 – 1020
35 ASR output (right) command ASR OUTP DIR R 39603 mA
01010101
01010101
01010101
01010101
0
01010101
41 Output signal (0 – 7) D-OUT-0------7 40955 0:OFF/1:ON
01010101
42 Output signal (8 – 15) D-OUT-8-----15 40956 0:OFF/1:ON
01010101
43 Output signal (16 – 23) D-OUT-16----23 40957 0:OFF/1:ON
14 HD465-7R, HD605-7R
Detailed information of 40932 (D-IN--0------7) Detailed information of 40955 (D-OUT--0------7)

[0] : (Unused) [0] : Auto-suspension solenoid 1
[1] : Service brake switch [1] : Hoist selector valve
[2] : (Unused) [2] : Lever kick-out solenoid
[3] : Retarder switch (Rear) [3] : Auto-suspension solenoid 2
[4] : Validation switch 1 [4] : Front brake cut valve
[5] : Validation switch 2 [5] : (Unused)
[6] : Memory clear switch [6] : (Unused)
[7] : Brake oil filter [7] : (Unused)
Detailed information of 40933 (D-IN--8-----15) Detailed information of 40956 (D-OUT--8-----15)

[8] : ASR pressure switch (Rear left) [8] : (Unused)
[9] : ASR pressure switch (Rear right) [9] : (Unused)
[10] : Shut-off valve switch [10] : (Unused)
[11] : ASR check switch [11] : ASR shut-off valve
[12] : Parking brake pressure switch [12] : (Unused)
[13] : (Unused) [13] : (Unused)
[14] : (Unused) [14] : (Unused)
[15] : Secondary brake switch [15] : Body "Float" signal
Detailed information of 40934 (D-IN--16----23) Detailed information of 40957 (D-OUT--16-----23)

[16] : Starting switch C terminal signal [16] : Stop lamp relay
[17] : (Unused) [17] : (Unused)
[18] : (Unused) [18] : Sensor power supply (24 V)
[19] : Brake wear switch (Rear left) [19] : BCV relay
[20] : Brake wear switch (Rear right) [20] : (Unused)
[21] : (Unused) [21] : (Unused)
[22] : (Unused) [22] : (Unused)
[23] : (Unused) [23] : (Unused)

[24] : Steering wheel speed
[25] : (Unused)
[26] : Retarder cooling filter
[27] : Engine oil level switch
[28] : Engine oil filter
[29] : Steering/hoist oil level switch
[30] : Steering/hoist oil filter switch
[31] : Battery electrolyte level switch

[32] : Transmission/Brake oil level switch
HD465-7R, HD605-7R 15
VHMS [VHMS controller system]
Monitor-
ing code
Suspension pressure 32804 (*) 0.00 – 20.10
1 SUS PRESS (FR) MPa
(front right) ---- [Other than above]
0.00 – 20.10
2 Suspension pressure (front left) SUS PRESS (FL) 32805 (*) MPa
Suspension pressure 0.00 – 20.10
3 SUS PRESS (RR) 32806 (*) MPa
(rear right) ---- [Other than above]
0.00 – 20.10
4 Suspension pressure (rear left) SUS PRESS (RL) 32807 (*) MPa
5 SUS PRESS (FR) 32810 (*) V
0.00 – 5.00
6 Suspension pressure (front left) SUS PRESS (FL) 32811 (*) V
7 SUS PRESS (RR) 32812 (*) V
0.00 – 5.00
8 Suspension pressure (rear left) SUS PRESS (RL) 32813 V
-15.0 – +15.0
9 Inclinometer (pitch angle) INCLINOMETER 32901 (*) ° (degree)
0.00 – 5.10
10 Inclinometer (pitch angle) INCLINOMETER 32902 (*) V
-30 – +100
11 Ambient temperature AIR TEMP 37501 °C
0.00 – 5.00
12 Ambient temperature AIR TEMP 37504 V
01010101
01010101
0101
15 Output signal (0 – 7) D-OUT-0--3 40946 0:OFF/1:ON
0101
16 SEL signal (0 – 3) D-SEL--0--3 40947 0:OFF/1:ON
0.0 – 655.4
17 Payload PAYLOAD 42200 (*) t
0.0 – 655.4
18 Rated load weight RATE WEIGHT 42201 (*) t
19 Status of truck TRUCK STATUS 42400 (*) 0 – 8 —
20 Gearshift lever N signal SHIFT LEVER N 42500 (*) 0/1 (1 digit of 0/1) 0:OFF/1:ON
200 – 950
21 Exhaust temperature (front) EXHAUST TMP F 42610 °C
200 – 950
22 Exhaust temperature (rear) EXHAUST TMP R 42611 °C
16 HD465-7R, HD605-7R
VHMS [VHMS controller system]
Monitor-
ing code
0.00 – 5.00
23 Exhaust temperature (front) EXHAUST TMP F 42612 V
0.00 – 5.00
24 Exhaust temperature (rear) EXHAUST TMP R 42613 V
0.0 – 20.0
25 Blow-by pressure BLOWBY PRESS 42801 kPa
0.00 – 5.00
26 Blow-by pressure BLOWBY PRESS 42802 V
27 28. Stop and run flags STOP RUN FLAG 45000 (*) 0/1 (1 digit of 0/1) 0:OFF/1:ON
*: When PLM is set in VHMS.
HD465-7R, HD605-7R 17
Detailed information of 40944 (D-IN--0------7)

[0] : (Unused)
[1] : Connection of ORBCOM (Connected: 1)
[2] : (Unused)
[3] : (Unused)
[4] : Connection of PLM2 (Connected: 1)
[5] : (Unused)
[6] : Download switch under cab (ON: 1)
[7] : Body float state (ON: 1)
Detailed information of 40945 (D-IN--8-----15)

[8] : Protocol selector connector (Automatic
transmission: 1)
[9] : Protocol selector connector (MMS communi-
cation: 1)
[10] : (Unused)
[11] : (Unused)
[12] : (Unused)
[13] : (Unused)
[14] : (Unused)
[15] : (Unused)
Detailed information of 40946 (D-OUT-0--3)

[0] : External indicator lamp (Lighting of green lamp: 0)
[1] : External indicator lamp (Lighting of orange lamp: 0)
[2] : External indicator lamp (Lighting of red lamp: 0)
[3] : Operation of VHMS (Operating: 1)
Detailed information of 40947 (D-SEL-0--3)

[0] : SEL-0 (Always: 0)
[1] : SEL-1 (Always: 1)
[2] : SEL-2 (Always: 1)
[3] : SEL-3 (Always: 0)
Detailed information of 42400

[1] : Empty truck is stopped
[2] : Empty truck is traveling
[3] : Truck is being loaded
[4] : Loaded truck is traveling
[5] : Loaded truck is stopped
[6] : Truck is dumping
18 HD465-7R, HD605-7R
ABS [ABS controller system] (If equipped)
Monitor-
ing code
******** (8 digits/numerals
1 Part No. of software VERSION 20210 —
and symbols)
2 Version No. of application VERSION (APP) 20233 —
and symbols)
3 Version No. of data VERSION (DATA) 20234 —
and symbols)
0 – 3000
4 Wheel speed (front left) WHEEL SPEED FL 39706 rpm
0 – 3000
5 Wheel speed (front right) WHEEL SPEED FR 39707 rpm
0 – 3000
6 Wheel speed (rear left) WHEEL SPEED RL 39708 rpm
0 – 3000
7 Wheel speed (rear right) WHEEL SPEED RR 39709 rpm
01010101
8 Input signal (0 - 7) D-IN--0------7 40937 0:OFF/1:ON
01010101
9 Input signal (8 - 15) D-IN--8-----15 40938 0:OFF/1:ON
01010101
01010101
01010101
12 Output signal (0 - 7) D-OUT-0------7 40958 0:OFF/1:ON
01010101
13 Output signal (8 - 15) D-OUT-8-----15 40959 0:OFF/1:ON
01010101
14 Output signal (16 - 23) D-OUT-16----23 40960 0:OFF/1:ON
ABS control valve output 0 – 1000
15 ABS CNT VAL FL 43308 mA
(front left) ---- [Other than above]
16 ABS CNT VAL FR 43309 mA
17 ABS CNT VAL RL 43310 mA
(rear left) ---- [Other than above]
18 ABS CNT VAL RR 43311 mA
ABS control oil pressure 0.00 – 99.99
19 CONT PRESS FL 43312 MPa
20 CONT PRESS FL 43313 V
21 CONT PRESS FR 43314 MPa
22 CONT PRESS FR 43315 V
HD465-7R, HD605-7R 19
ABS [ABS controller system] (If equipped)
Monitor-
ing code
23 CONT PRESS RL 43316 MPa
24 CONT PRESS RL 43317 V
25 CONT PRESS RR 43318 MPa
26 CONT PRESS RR 43319 V
20 HD465-7R, HD605-7R
Detailed information of 40937 (D-IN--0------7) Detailed information of 40959 (D-OUT--8-----15)

[0] : ABS cut pressure switch (Front) [8] : (Unused)
[1] : ABS cut pressure switch (Rear) [9] : (Unused)
Detailed information of 40938 (D-IN--8-----15) Detailed information of 40960 (D-OUT--16-----23)

[10] : (Unused) [18] : ABS cut valve (Front) (* Through relay)
[11] : (Unused) [19] : ABS cut valve (Rear) (* Through relay)
[12] : (Unused) [20] : (Unused)
[13] : (Unused) [21] : (Unused)
[14] : (Unused) [22] : (Unused)
[15] : (Unused) [23] : (Unused)

[16] : Starting switch C terminal signal
[17] : (Unused)
[18] : (Unused)
[19] : (Unused)
[20] : (Unused)
[21] : (Unused)
[22] : (Unused)
[23] : (Unused)

[24] : (Unused)
[25] : (Unused)
[26] : (Unused)
[27] : (Unused)
[28] : (Unused)
[29] : (Unused)
[30] : (Unused)
[31] : (Unused)
Detailed information of 40958 (D-OUT--0------7)

[0] : (Unused)
[1] : (Unused)
[2] : (Unused)
[3] : (Unused)
[4] : (Unused)
[5] : (Unused)
[6] : (Unused)
[7] : (Unused)
HD465-7R, HD605-7R 21
[13] Cylinder cut-out mode (CYLINDER CUT- 3. Setting cut-out cylinder

OUT) In the reduced cylinder mode execution
As one method of troubleshooting for the engine, screen, operate the switches [>], [<], [U] and
the machine monitor has a reduced cylinder mode [t] to select the cut-out cylinder.
that can set the desired cylinder to the no injection q [ > ]: Selector cursor moves to the right.
condition. q [ < ]: Selector cursor moves to the left.
q [U]: Determine the cylinder.
1. Starting engine q [ t]: To return to the service menu selec-
Use this function while the engine is running, tion screen.
because a defective cylinder is determined a When the [U] switch is used to confirm
depending on the engine speed in the reduced the cut-out cylinder, communication is car-
cylinder mode. ried out between the machine monitor and
engine controller. During this time, the cyl-
2. Selection in the service menu inder No. flashes.
1) Select the reduced cylinder mode (CYLIN- After completion of the communication,
DER CUT-OUT) in the service menu the segment under the cylinder No.
selection screen. becomes black to show that the cylinder
has been cut out.
a A single cylinder or multiple cylinders can
be cut out.
2) With the cylinder cut-out mode selected,

press the [U] switch and display the
reduced cylinder mode execution screen.
q [U]: Execute the service menu.
4. Canceling cylinder cut-out
a The cylinder No. and the engine
Cancellation of cylinder cut-out is done by the
speed are displayed on the upper
same procedure as setting cut-out cylinder.
line, and the final injection amount
a When the [U] switch is used to confirm
command is displayed on the lower
the cancellation of the cut-out cylinder,
line.
communication is carried out between the
a When being switched to the reduced
machine monitor and engine controller.
cylinder mode execution screen, the
During this time, the cylinder No. flashes.
cursor of cylinder selection is always
After completion of the communication,
displayed under the No.1 cylinder.
the segment under the cylinder No.
becomes white to show that the cylinder
cut-out has been canceled.
22 HD465-7R, HD605-7R
[14] No injection cranking function 3. Setting is rejected during engine running

(NO INJECTION) During engine running, if the setting of no in-
The machine monitor has the function of no injec- jection cranking is attempted, "STOP ENGINE"
tion cranking, which is used for cranking after long- is displayed in the lower line, and setting is re-
term storage, stopping fuel injection of all the cylin- jected.
ders without starting the engine. a No injection cranking function cannot be
a The function of no injection cranking must be used during engine running.
operated under the condition that the engine is
stopped.
1. Selection in the service menu

In the service menu selection screen, select no
injection cranking function (NO INJECTION).
4. Canceling no injection cranking

If the [t] switch is pressed on the no injection
cranking execution screen, the screen returns
to the service menu selection screen and the
no injection cranking is cancelled.
q [t]: To return to the service menu selec-
2. Establishment of no injection cranking tion screen.
With the no injection cranking selected, press
the [U] switch to display no injection cranking
execution screen.
q [U]: Execute the service menu.
a If "CRANKING READY" is displayed on
the lower line, the none injection cranking
is set.
a If the starting switch is operated to the
START position under this condition, the
engine cranks but will not start.
HD465-7R, HD605-7R 23
[15] Adjustment function (TUNING) The adjustment is implemented by operating the

Machine monitor can run "Adjusting transmission machine monitor and machine body following the
ECMV electric current" and "Reset the transmission procedures below.
initial learning and execute learning " through the 1. Preparing operations for "Adjusting transmis-
transmission controller. sion ECMV electric current"
(Real time monitoring function)
2. Adjusting transmission ECMV electric current
(02: AUTO of ECMV TUNING)
3. Reset the transmission initial learning and
implement learning (TUNED/Real-time moni-
toring function for 01: TM TRIGGER)
a ( ) indicates service menu or adjustment func-
tion used for the adjustment.
a [MANUAL] menu of [02: ECMV TUNING] is the
function only used by plants and not used for
field services.
a For details concerning the operation method of
real time monitoring function, refer to "[11] real
time monitoring function".
When power train related operation such as the fol-
lowing is carried out, execute the adjustment oper-
ation.
q When transmission is overhauled or changed
q When transmission valve is replaced
q Transmission controller has been replaced.
q When an abnormality occurred in the power
train speed sensor and has been repaired
(refer to the table below for failure code)
q If the transmission oil temperature sensor is
troubled and repaired (refer to the table below
for failure code)
q If the transmission oil filter is clogged and
repaired (refer to the table below for failure
code)
1. Preparing operations for "Adjusting trans-
Failure code Device name mission ECMV current"
DLF1KA a The adjusting operation should be carried
Transmission input shaft speed
sensor out with the specified oil temperature.
DLF1LC
Confirm the machine is not displaying
DLF2KA Transmission intermediate shaft abnormality and adjust the transmission oil
DLF2LC speed sensor temperature following the next procedure.
Transmission output shaft speed 1) Select real time monitoring function
DLF3KA (REAL-TIME MONITOR) in the service
sensor
menu selection screen.
Transmission oil temperature
DGF1KX
sensor
15BONX Transmission oil filter
24 HD465-7R, HD605-7R
2) With the service menu selected, press the 7) Keep depressing the brake pedal, and set
[U] switch to display the monitoring sys- the gear shift lever to D position.
tem and function selection screen. a Confirm that the shift indicator dis-
q [U]: Execute service menu plays "F2".
3) In the monitoring system and function 8) Stall the torque converter to raise the
selection screen, press [>] switch or [<] transmission oil temperature up to 70 – 80
switch to select transmission system °C.
(TRANSMISSION). a Be careful not to overheat the oil
q [>]: To proceed to next monitoring while stalling the torque converter.
system and function 9) Return the gear shift lever to "N" position,
q [<]: To go back to previous monitoring keep it for 3 minutes, and confirm that the
system and function transmission oil temperature is stable
between 70 – 80 °C.
a In addition to the above, check that
the machine has not detected a trou-
ble.
2. Adjusting transmission ECMV current

a Adjustment is carried out four times auto-
matically against the Hi, Lo, R, 1st, 2nd,
3rd, and 4th valves respectively.
1) Refer to "1. Preparating operations for
adjusting transmission ECMV electric cur-
rent", and select the monitoring code of
transmission oil temperature.
q Monitoring code:
4) With the transmission system selected, 32500 (T/M OIL TEMP)
press the [U] switch to display the moni- a At this time, do not start the engine.
toring display and item selection screen.
q [U]: Execute 1 system individual
monitoring
q The program version No. is displayed
on ********.
5) In the monitoring display and item selec-
tion screen, press [>] switch or [<] switch
to select monitoring code of transmission
oil temperature.
q [>]: To preceed to the next monitoring
item
q [<]: To go back to the previous moni-
toring item
q Monitoring code:
32500 (T/M OIL TEMP) 2) Run the engine, set the machine to the
next condition, and confirm that the trans-
mission oil temperature is between 70 –
80 °C.
q Parking break switch: PARKING
q AISS LOW switch: LOW (low speed)
q Gear shift lever: N position
q Engine: Low idling
q Accelerator pedal: OFF (Released)
6) Confirm that the parking brake switch is

set to PARKING, and start the engine.
HD465-7R, HD605-7R 25
3) Return to the service menu selection a The figure shows the state in which
screen, and select the adjustment function the automatic compensation is
(TUNING). selected, therefore, [AUTO] is indi-
a Press [t] switch several times to cated in the lower line. In the state in
return to the service menu selection which the manual compensation is
screen. selected, [MANUAL] is indicated in
the lower line.
4) While the service menu is selected, hold

down the [U] switch for a minimum of 5 7) Confirm the machine condition again and
seconds to display the adjustment menu press the [U] switch to start adjustment.
selection screen. q [U] switch: To start the adjustment
q [U]: Execute service menu a The lower line display changes from
5) On the adjustment menu selection screen, "IP" to "IP ***".
press [>] switch or [<] switch, to select
ECMV current adjustment item (02: ECMV
TUNING).
q [>]: To proceed to the next adjust-
ment item
q [<]: To go back to the previous adjust-
ment item
a Adjustments are carried out 4 times

c on ti nu ou sl y f or eac h o bj ec ti v e
clutch, and the table below is dis-
played.
No. Valve 1st time 2nd time 3rd time 4th time
1 LOW IP L-1 IP L-2 IP L-3 IP L-4
6) With the adjustment item selected, press 2 HIGH IP H-1 IP H-2 IP H-3 IP H-4
[U] switch to display the automatic com- 3 1ST IP 1-1 IP 1-2 IP 1-3 IP 1-4
pensation (AUTO) or manual compensa-
4 2ND IP 2-1 IP 2-2 IP 2-3 IP 2-4
tion (MANUAL) selection screen. Press
[<] switch or [>] switch to select the auto- 5 3RD IP 3-1 IP 3-2 IP 3-3 IP 3-4
matic compensation (AUTO). 6 REV IP R-1 IP R-2 IP R-3 IP R-4
q [U]: To execute the adjustment menu 7 4TH IP 4-1 IP 4-2 IP 4-3 IP 4-4
q [ > ]: To switch to the next compensa-
tion screen.
q [ < ]: To go back the previous com-
pensation screen.
q Compensation menu: AUTO
26 HD465-7R, HD605-7R
8) Normal and abnormal results are dis- 3. Reset the transmission initial learning and
played for each adjustment, therefore take implementation of learning
action depending on the display. a Before carrying out this adjustment item,
be sure to implement "2. Transmission
ECMV current adjustment".
a Before proceeding to the learning, confirm
that the transmission oil temperature is at
the specified temperature referring to "1.
Preparing operations for "Adjusting trans-
mission ECMV current". (If adjustments
are made at temperatures other than speci-
fied temperature, time lag or gear shifting
shock may occur.)
k The learning should be carried out in
an area with a sufficient traveling dis-
tance, paying attention to the sur-
q Indicated code for the normal or abnormal re- roundings for safety.
sult 1) Select the adjusting function (TUNING) in
Code Condition the service menu selection screen.
OK Normal result
NG1 Out of compensation conditions
Abnormal
NG2 No fill
result
NG3 Over the compensation values
q If "OK" (normal result) is displayed:
q Adjustment is done without error.
q If "NG1" is displayed (out of compensation
condition):
q Adjust the transmission oil temperature ex-
actly, and confirm the machine setting condi-
tions again, then carry out the adjustment from
procedure 1).
q If "NG2" (no fill) is displayed: 2) With the service menu selected, hold
q Carry out troubleshooting of failure code down the [U] switch for a minimum of 5
[15S*MA][DDT*KA], and if the condition is seconds to display the adjustment menu
confirmed to be normal, then start again from selection screen.
procedure 1) (The symbol with * mark varies q [U]: Execute the service menu.
by objective clutches). 3) On the adjustment menu selection screen,
q If "NG3" is displayed (compensation value confirm that the transmission trigger
over): adjustment item (01: TM TRIGGER) is dis-
q Carry out troubleshooting of failure code played.
[15S*L1], and if the condition is confirmed to
be normal, then start it again from procedure
1) (The symbol with * mark varies by objective
clutches).
9) If the adjustments has been completed nor-
mally, the adjustment values are recorded
in the transmission controller about 3 sec-
onds after the starting switch has been
turned off.
a If the starting switch needs to be
turned ON soon after the adjustment,
keep the starting switch in the OFF
position for more than 10 seconds as
a precautionary measure, then turn it
ON.
HD465-7R, HD605-7R 27
4) With the adjustment menu selected, press

the [U] switch to display the initial learn-
ing resetting screen.
q [U]: To execute the adjustment menu
a The current initialization state is dis-
played in the lower line.
q Initialization is done: INITIAL STATUS
q Initialization is not yet done: TUNED
a If [TUNED] is indicated, proceed to
the next procedure to initialize the
learning data.
a If the resetting operation is to be
aborted, press [t] switch to return to
the previous screen.
7) Return to service menu selection screen
q [t]: To return to the previous screen
and select real time monitoring function
(REAL-TIME MONITOR).
a Press [t] switch several times to
return to the service menu selection
screen.
5) With the initial learning resetting screen

displayed, press the [U] switch to display
the initializing operation screen.
q [U] switch:
To execute the initial learning reset
8) With the service menu selected, press the
[U] switch to display the monitoring sys-
tem and function selection screen.
q [U]: To execute the service menu.
9) In the monitoring system and function
selection screen, press [>] switch or [<]
switch to select 2 items simultaneous
monitoring (2 ITEMS).
q [>]: To proceed to next monitoring
system and function
q [<]: Go back to previous monitoring
system and function
6) With the initialization operation screen dis-

played, operate each of the switches [<],
[>] and [t] to execute initialization.
q [ < ]: To select YES (The cursor moves)
q [ > ]: To select NO (The cursor moves).
q [t]: Execute YES or NO
a After initializing, confirm that the dis-
play on the lower line indicates that
initialization is completed.
q Initialization is done: INITIAL STATUS
28 HD465-7R, HD605-7R
10) With 2 items simultaneous monitoring se-

lected, press the [U] switch to display the
monitoring code input screen.
q [U]: Execute monitoring system and
function.
11) In the monitoring code input screen, oper-
ate the switches [>], [<], [U] and [t], to
input two monitoring codes directly.
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases
mined
q [ t]: Cursor moves to the left end / To
return to the monitoring system
15) Set the gearshift lever to the "6" position
and function selection screen.
and depress the accelerator pedal fully to
q Monitoring code: 32500 and 38920
run the truck and shift up the gear to F6.
a Indicate the transmission oil tempera-
a Shift up: F1 o F2 o F3 o F4 o F5 o
ture in the upper row (32500) and
F6
study condition of clutch trigger in the
16) After the gear is shifted up to F6, release
lower row (38920) (0: not learned yet,
the accelerator pedal and shift down the
1: already learned).
gear to F1 by coasting run.
a Shift down: F6 o F5 o F4 o F3 o F2
o F1
a Do not apply the brake during coast-
ing run.
17) Check that the trigger learning of the 4th
clutch is displayed on the monitor.
a If "1" is displayed, go to the next step.
a If the display is "0", repeat procedure
15) – 16) until it becomes "1".
a If "1" is not displayed after repeating
the steps 4 times, the ECMV may be
defective. In this case, replace the
ECMV.
12) Set AISS LOW switch to LOW. a The * marked clutch display can be
13) Start the engine, keep the gear shift lever either "0" or "1".
at N position for 10 seconds with engine at
the low idle, then operate the gear shift
lever as follows.
a Gear shift lever operation:
NoRoN
14) Confirm the trigger learning display of R
clutch in the monitoring display.
a Proceed to the next step if the display
is "1".
a If the display is "0", repeat procedure
13) until it becomes "1".
ECMV.
a The * marked clutch display can be
either "0" or "1".
HD465-7R, HD605-7R 29
18) Set the gearshift lever to the "4" position 23) Check that the trigger learning of the Hi
and depress the accelerator pedal fully to clutch is displayed on the monitor.
run the truck and shift up the gear to F4. a If "1" is displayed, go to the next step.
a Shifting up: F1 o F2 o F3 o F4 a If "0" is displayed, repeat steps 21) –
19) After running the machine at F4 for 10 23) until "1" is displayed.
seconds, release the accelerator pedal a If "1" is not displayed after repeating
and shift down the gear to F1 by coasting the steps 4 times, the ECMV may be
run. defective. In this case, replace the
a Shifting down: F4 o F3 o F2 o F1 ECMV.
a Do not apply the brake during coast- a The * marked clutch display can be
ing run. either "0" or "1".
20) Check that the trigger learning of the 2nd
a If "1" is displayed, go to the next step.
a If "0" is displayed, repeat steps 18) –
20) until "1" is displayed.
ECMV.
a The * marked clutch display can be
either "0" or "1".

shift up the gear to F3 and then continue
travel at F3, adjusting the accelerator
pedal.
a Shifting up: F1 o F2 o F3
25) After running the machine at F3 for 10
seconds, depress the accelerator pedal
fully to shift up the gear to F4.
a Shifting up: F3 o F4
26) Stop the machine and check that the trig-
21) Set the gearshift lever to the "3" position ger learning of the low clutch and 3rd
and depress the accelerator pedal fully to clutch is displayed on the monitor.
run the truck and shift up the gear to F3. a If "1" is displayed, go to the next step.
a Shifting up: F1 o F2 o F3 a If "0" is displayed, repeat steps 24) –
22) After running the machine at F3 for 10 26) until "1" is displayed.
seconds, release the accelerator pedal a If "1" is not displayed after repeating
and shift down the gear to F1 by coasting the steps 4 times, the ECMV may be
run. defective. In this case, replace the
a Shifting down: F3 o F2 o F1 ECMV.
a Do not apply the brake during coast- a The * marked clutch display can be
ing run. either "0" or "1".
30 HD465-7R, HD605-7R
30) In the monitiring display, confirm finally the

trigger learning display of lower line.
a If displayed as the drawing below, the
initial learning has completed nor-
mally.

run the truck and shift up the gear to F2.
a Shifting up: F1 o F2
28) After running the machine at F2 for 10
seconds, release the accelerator pedal 31) Press [t] switch sereral times to exit the
and shift down the gear to F1 by coasting service menu.
run. q [t]: To return to the previous screen.
a Shifting down: F2 o F1
29) Check that the trigger learning of the 1st
a If "1" is displayed the initial learning
has completed finally.
a If "0" is displayed, repeat steps 27) –
29) until "1" is displayed.
ECMV.
HD465-7R, HD605-7R 31
[16] Filter and oil replacement time setting func- a Displayed maintenance item and
tion (MAINTENANCE MONITOR) function:
Machine monitor can set the maintenance intervals
Maintenance items
for various filters and oil which become the base of No. Display
and functions
replacement time display for filter and oil. Also the
machine monitor can activate or deactivate the dis- 1 41:FUEL P FILT Fuel pre filter
play function. 2 01:ENG OIL Engine oil
1. Selection of the service menu 3 02:ENG FILT Engine oil filter
Select the filter and oil replacement time set-
4 13:TM FILT Transmission oil filter
ting function (MAINTENANCE MONITOR) in
the service menu selection screen. 5 03:FUEL FILT Fuel main filter
6 06:CORR RES Corrosion resistor
Torque converter/
7 17:TC/TM/ BK OIL
Transmission/Brake oil
8 14:BK OIL FILT Brake oil filter
9 16:BK C FILT Brake cooling oil filter
10 04:HYD FILT Hydraulic oil filter
11 11:DIFF OIL Differential oil
12 08:FNL OIL Final drive oil
13 10:HYD OIL Hydraulic oil
Setting default value for all
14 INITIALIZE
items
Setting validity or invalidity for
15 ALL ITEMS
2. Displaying and selecting the maintenance item all items
and function
1) With the service menu selected, press the a No.1 – 13 are the maintenance items
[U] switch to display the maintenance where the setting is changed by item,
item and function selection screen. and No.14 – 15 are the functions
q [U]: Conduct the service menu. which allows to change the setting of
all items simultaneously.
a The item and function is displayed in
the [*] section.
2) If [>] switch or [<] switch is pushed while

the maintenance item and function selec-
tion screen is displayed, the maintenance
item and function will be displayed end-
lessly in the order shown by the below
table. Select the item or the function
which will be used.
q [>]: To proceed to next maintenance
item and function.
q [<]: To return to the previous mainte-
nance item and function.
32 HD465-7R, HD605-7R
3. Display contents of the maintenance item

(Items No.1 – 13)
If the maintenance item for filter or oil is
selected, the following contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set item
2: Remaining time to set replacement time
3: Number of times of replacement up to
present
3) When the interval time is completely

determined, the screen to confirm the
changes is displayed. Then, operate the
switches [<], [>] and [t].
q [ <]: Select YES (move cursor)
q [ >]: Select NO (move cursor)
4. Changing the interval time by maintenance

item (Items No.1 – 13)
1) With the item to change the interval time
(ex: P FUEL FILT) selected on the mainte-
nance item and the function selection
screen, press the [U] switch to display the
interval change screen.
q [U]: Execute the function to change
maintenance item.
a The current set interval is displayed
on the screen.
a With this screen displayed, if the [>] 5. Set the function activation or deactivation by
switch or the [<] switch is operated, maintenance item (items No.1 – 13).
the screen switches to the setting 1) With the item (ex: FUEL P FILT) to change
screen for enable or disable the main- the enable or disable of the function
tenance item. selected on the maintenance item and
2) On the interval change screen, operate function selection screen, press the
the switches [>], [<], [U] and [t] to input [U]switch to display the interval input
the interval time. screen.
q [ > ]: Number at the cursor increases. q [U]: Execute the function to change
q [ < ]: Number at the cursor decreases. maintenance item.
mined.
q [ t]: To return to the service menu
selection screen.
a The time must always be input with 4
digits. For the time with less than 4
digits, input 0s in place of the vacant
number.
HD465-7R, HD605-7R 33
2) After the screen to input intervals is dis- a If the timer which has been OFF is
played, press the [>] switch or the [<] turned ON, the interval is set to the
switch to display the activation or deacti- value before it was turned OFF and
vation setting screen. the rest of set time of the timer is
q [>]: Switch the setting screen. reset. The number of resetting times
q [<]: Switch the setting screen is set to the value before it was turned
a If the function is activated, it is dis- OFF.
played like the upper line. And if it is
deactivated, it is displayed like the 6. Setting default values of interval time for all
lower line. items (function of No.15)
3) After the activate or deactivate setting 1) With all item default value setting (INI-
screen is displayed, check the present TIALIZE) selected on the maintenance
setting status and the contents of change. item and function selection screen, press
Then operate the switches [U] or [t]. the [U] switch to display the all item
q [U]: Switch to the change confirma- default value setting screen.
tion screen q [U]: Execute the function to set the
q [t]: To return to the maintenance default values of all the items.
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
2) After the all item default value setting

screen is displayed operate [<], [>] and
[t] switches.
4) When the change confirmation screen is q [ >]: Select NO (move cursor)
displayed, operate each [<], [>] and [t] q [t]: Execute YES or NO
switches.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
a All the items are set to their respec-

tive default values, regardless of the
ON or OFF state of each item.
a The rest of the set time of the timer is
set to the [default value/elapsed time
after the previous replacement].
34 HD465-7R, HD605-7R
a The number of resetting times is kept a If activation of all the items (ON) is
at the value before the default was set, the maintenance function of all
set. the items starts to work regardless of
a Each item is set turned ON. the setting of each maintenance item
and the interval is set to the previous
7. Setting the function activation or deactivation time before the interval has been
for all the items (function No.16) deactivated.
1) With the activation or deactivation setting a The timer is reset simultaneously and
for all items selected (ALL ITEMS) on the it restarts to count from 0 h.
maintenance item and function selection The number of resetting times is set
screen, press the [U] switch to display the to the value before it was turned OFF.
all items activation or deactivation setting
screen.
q [U]: Implement the function to set
activation or deactivation of all
the items.
4) When the change confirmation screen is

displayed, operate each [<], [>] and [t]
switches.
q [ >]: Select NO (move cursor)
2) After the all items activation or deactiva- q [t]: Execute YES or NO
tion setting screen is displayed, press the
[>] switch or the [<] switch to display the
activation setting or deactivation setting
screen.
q [>]: Switch the setting screen.
q [<]: Switch the setting screen
a To deactivate all the items, display the
upper line setting screen (OFF), and
to activate all the items, display the
lower line setting screen (ON).
3) Confirm the setting screen, press the [U]
switch or the [t] switch to display the
change confirmation screen.
q [U]: To switch to the change confir-
mation screen.
q [ t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
a If deactivation of all the items (OFF) is
set, it will stop the maintenance func-
tion of all the items, regardless of the
setting of each maintenance item.
HD465-7R, HD605-7R 35
Table of filter and oil replacement time set items

Replacement frequency
No. System and function Code Display Remarks
(Default value)
1 Fuel pre filter 41 FUEL P FILT 500
2 Engine oil 01 ENG OIL 500
3 Engine oil filter 02 ENG FILT 500
4 Transmission oil filter 13 TM FILT 500
5 Fuel main filter 03 FUEL FILT 500
6 Corrosion resistor 06 CORR RES 1000
Torque converter/Transmission/ TC/TM/
7 24 1000
Brake oil BK OIL
8 Brake oil filter 14 BK OIL FILT 1000
9 Brake cooling oil filter 16 BK C FILT 1000
10 Hydraulic oil filter 04 HYD FILT 2000
11 Differential oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
All item simultaneous
14 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
15 Setting enable or disable for all items (None) ALL ITEMS —
setting function
36 HD465-7R, HD605-7R
[17] Operation information display function a There are four types of information
(OPERATION INFO) screen.
Machine monitor can display the fuel consumption
per mile and per time, the fuel consumption per any 4. Information to be displayed (screen 1 – 4)
accumulated time and the travel distance, and the Above: Fuel consumption per km or mile from
fuel consumption during any accumulated time and the last reset point (distance unit is km
its accumulated time. or mile and it depends on the setting of
a Fuel consumption value is the integration of the integrated odometer in the opera-
the targeted injection rate signal which is sent tor mode).
from the engine controller. It is not the mea- Maximum display value:
surement of the actual fuel consumption. 99999.9 L/km (L/mile)
Therefore the displayed fuel consumption is Below: Fuel consumption per time started
used as a guide value. from the last reset point
Maximum display value: 99999.9 L/h
1. Selection of the service menu
Select the operation information display func-
tion (OPERATION INFO) on the service menu
selection screen.
Above: Integrated fuel consumption started

from the last reset point
Maximum display value: 9999999.9 L
Below: Accumulated travel distance from the
2. Displaying the operation information
last reset point (travel distance unit is
With the service menu selected, press the
km or mile and it depends on the set-
[U]switch and display the operation informa-
ting of the integrated odometer in the
tion and item selection screen.
operator mode).
Maximum display value:
9999999.9 km (mile)
3. Selecting displayed information

With the operation information and item selec-
tion screen displayed, operate the [>] switch or
the [<] switch to select the information screen
to display.
q [>]: To display the next information
screen.
q [<]: To display the previous informa-
tion screen.
HD465-7R, HD605-7R 37
Above: Integrated fuel consumption started

from the last reset point
Maximum display value: 9999999.9 L
Below: Elapsed time from the last reset point
Maximum display value: 9999999.9 h
6. Correction of integrated fuel consumption

a When there is the difference between the
integrated fuel consumption (L) in display
and the actually measured fuel consump-
tion, correct it in the following way.
a In case of "PLM function in VHMS" equpped.
1) With the reset screen displayed, press the
Above: Loading weight started from the last
[>] switch or the [<] switch to display the
reset point. [ton]
fuel consumption correction screen.
Below: Number of loading times from the last
q [>]: Switch the displayed screen
reset point. [times]
q [<]: Switch the displayed screen
5. Resetting displayed information 2) After the fuel consumption correction

1) With any information screen displayed, screen is displayed, press the [U] switch
press the [U] switch to display the reset or the [t] switch to switch to the correction
screen. value input screen.
q [U]: Switch to the reset screen. q [U]: Switch to the correction value
2) After the reset screen is displayed, press input screen
the [U] switch or the [t] switch to execute q [t ]: To return to the service menu
or cancel the reset. screen
q [U]: Implement resetting.
q [ t]: Cancel resetting
a When the resetting is carried out, all
the information goes to "0", and the
monitoring starts newly from that
point of time (Monitoring is only con-
ducted while engine is running.)
a If the [>] switch or the [<] switch is
operated with this screen displayed,
the screen is switched to the fuel con-
sumption correction screen.
38 HD465-7R, HD605-7R
3) After the compensation value input screen

is displayed, operate each of the switches
[>], [<], [U] and [t] to input the compen-
sation value directly.
q [ > ]: To switch the sign (+/-) / Number
increases.
q [ < ]: To switch the sign (+/-) / Number
decreases.
q [U]: Sign/number at the cursor is
determined.
q [ t]: Return to the fuel consumption
correction screen
a The correction value at the plant
before shipment is [+/-00.0%] (In
3. Selection of mode
case of inputting 00.0, +/- does not
While the service menu is selected, press the
matter.)
[U] switch to display the engine mode fixing
a The compensation value can be input
screen.
within the range of [-50.0% –
q [U]: Execute service menu
+50.0%].
4. Selection of displayed information

[18] Engine mode fixing function (FIX POWER While the engine mode fixing screen is dis-
MODE) played, select the information screen to be dis-
While the screen is displayed, the operator can played with the [>] or [<] switch.
measure the high idle speed and torque converter q [ > ] switch: Switch setting screen
stall speed to check the engine performance. q [ < ] switch: Switch setting screen
q Engine speed at high idling q [t] switch: Engine mode fixing function
q Engine speed at torque converter stall a The mode is four kind of A – D.
If a mode is selected by the following operation, it is
sent to the transmission controller, which sends it to 5. Finishing of display
the engine controller. Press the [t] switch to return to the engine
1. Advance check mode fixing function screen.
Before the operation, check the following q Fixing of the engine mode is reset.
items.
q Parking brake: ON (Parking)
q Failure code: Not displayed
a Refer to "Standard valve table" for mode
and value.
2. Selection of service menu

While the service menu selection screen is dis-
played, select the engine mode fixing function
(FIX POWER MODE).
HD465-7R, HD605-7R 39
[19] Manual snapshot function (SNAPSHOT) 3. Press [U] switch to start the snapshot.
q This function is applicable to only machines a The upper column displays the elapsed
equipped with VHMS. time.
q The manual snapshot function stores 7 min- a [–] sign in the leftmost position of the lower
utes and 30 seconds worth data to be used for column is replaced with [*] and it starts
Pm clinic or testing/adjustment to VHMS con- flashing.
troller. a For every 30 seconds, [–] is replaced with
q When collecting data at a regular interval for [*] starting with the leftmost one. When
Pm clinic, it is required to operate the machine two or more [*] signs are displayed, the
as per the procedure specified for the quick rightmost one flashes.
Pm. As for the data collection for the testing or a Pressing [t] switch while the snapshot is
adjustment purpose, however, no machine taking place stops the snapshot.
operation is requested.
q When using the data being stored with the
manual snapshot function, a PC must be con-
nected. For the connecting procedure, refer to
VHMS controller initial setting procedure.
(Connection of a PC may be done before or
after the snapshot.)
a For detail of operation of the snapshot function,
see the Quick Pm implementation procedure.
1. Display the manual snapshot function screen

from the menu screen of service mode.
4. Referring to the Pm clinic implementation pro-

cedure operate the machine operation.
a After 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be dis-
played for 11th through 15th positions.
q *: Indicates the data sampling interval is
once every 10 seconds.
q #: Data sampling interval is once every 1
second.
5. As 7 minutes and 30 seconds elapsed from

start of the snapshot, following screen appears
2. Pressing [U] switch to display the ready and then the initial screen is restored in 5 sec-
screen (READY). onds later.
a The lower column displays 15 pieces of [–] (End of snapshot)
sign.
40 HD465-7R, HD605-7R
[20] PLM setting function (PLM)

q This function is applicable when the PLM is
installed in the VHMS.
Set various items of the payload meter (PLM) with
the machine monitor.
Refer to "Setting of payload meter built in VHMS"
for details.
[23] Initializing function (INITIALIZE)

a This function is exclusive for the plant, and is
not used for field service.
[21] Option selection function

(OPTIONAL SELECT)
Machine monitor can set and adjust various
optional devices which have been installed or
removed.
a Refer to the item of "Setting and adjusting vari-
ous equipment", for the operating method of
this function.
[22] Model selection function (MACHINE)

Machine monitor is common among many models,
and if the machine monitor is replaced, select the
same model as the one currently installed.
a Refer to the item of "Setting and adjusting vari-
ous equipment", for the operating method of
this function.
HD465-7R, HD605-7R 41

© 2007 KOMATSU
All Rights Reserved
42 HD465-7R, HD605-7R
SEN02532-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up

VHMS controller initial setting procedure........................................................................................................ 2
Precautions for replacing VHMS controller ................................................................................................... 23
Pm Clinic check sheet................................................................................................................................... 29
Initial setting of payload meter ...................................................................................................................... 32
Setting of payload meter built in VHMS ........................................................................................................ 33
Setting of card-type payload meter (PLM- ) after installation or replacement............................................. 41
HD465-7R, HD605-7R 1
VHMS controller initial setting 1. Confirmation of machine information,

engine information, transmission controller
procedure 1 information and controller information
a Testing instrument a This confirmation procedure is targeted at
the entire machine.
Confirm and record the machine informa-
1 799-608-3211 Diskette tion, engine information, VHMS controller
2 799-608-3220 Wiring harness information and ORBCOM terminal infor-
N Note type PC mation.
Commercially
3 (With windows 98/2000/Me/ No. Information to be confirmed
available
XP and terminal "RS232C")
1 Model name
a Initial setting of VHMS controller shall be done 2 Machine serial No.
according to the following procedure. This 3 Current service meter hour
operation is needed prior to a full-scale opera- 4 Engine serial No.
tion of a machine being delivered and assem-
5 Transmission serial No.
bled in the field, or prior to resumption of its
operation after a long time of storage. 6 VHMS controller serial No.
a Machine data collected with VHMS controller ORBCOM terminal serial No.
7
are stored and managed on WebCARE data- [Only for machines equipped with ORBCOM]
base. In order to endure smooth data process-
ing on WebCARE , consistency must be 2. Connecting a PC
provided among the settings done on VHMS a This work is done inside the cab.
controller. Inconsistencies in the settings 1) Make sure the starting switch is at OFF
obstruct loading of data to WebCARE, ham- position.
pering appropriate use of VHMS data. The ini- k Before connecting or disconnect-
tial setting, therefore, is a must. ing a PC, be sure to turn off the
a For the method of installing the VHMS Initial starting switch.
setting Program to the personal computer, 2) Using harness N2, connect the PC N3 and
refer to the Operation and Maintenance Man- download connector DPC7.
ual contained in the package of diskette N1. a Connect RS232C terminal of the PC.
a In the procedure, service menus of the monitor
panel are used. Thus, it is advisable to refer-
ence the information contained in the "Special
functions of monitor panel" to understand their
procedure beforehand.
a The initial setting procedure is described in the
ORBCOM installation specification and the
ORBCOM-less specification. When using the
ORBCOM installation specification, implement
the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOM
installation specification.
a Check each step of the setting work referenc-
ing the VHMS initial setting work check sheet.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
2 HD465-7R, HD605-7R
a Download connector DPC7 is installed

to box (1) behind the cover at the rear
of the operator's seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOM controller
has captured the communication satellite.
[ORBCOM installation specification]
a Check whether or not ORBCOM con-
troller is capturing the communica-
tion satellite from VHMS controller.
a Perform this check within 3 minutes
after the VHMS starts.
a If the decimal point LED of the right-
hand 7-segment LED blinks slowly,
the ORBCOMM controller is operat-
ing normally.
q Communication between the termi-
3. Confirming VHMS controller operation and nals is normal. The terminals have
confirming satellite capturing state transmission data and have captured
a This work is done inside the cab. the satellite.
a Confirmation of capturing of the satellite is
requested only for [ORBCOM installation
specification].
1) Set the starting switch to ON position.
2) Check the controller for normal operation
referencing 7-segment LED of VHMS con-
troller.
a The VHMS controller is powered with
the accessory power supply. Accord-
ingly, when the starting switch is set
to ON position, the 7-segment LED
must blink to display rotation and then
count up in hexadecimal notation. If
the LED operates in this way, the – Other states –
VHMS controller is operating nor- q OFF: The terminals cannot communi-
mally. cate with the ORBCOMM terminal.
q ON: Communication between the ter-
minals is normal. The terminals have
not captured the satellite.
q Quick blink: Communication between
the terminals is normal. The terminals
do not have transmission data but
have captured satellite.
HD465-7R, HD605-7R 3
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Turn on the PC power and start the OS. a This work is done inside the cab (from
2) Operating [VHMS initial setting tool] icon on PC).
the PC, start up the VHMS initial setting tool. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
Important [Machine Information]
a Appearance of the setup screen of 1) Open [Machine Information] tab.
the VHMS setting tool depends its a [Data clear and Set up] menu displays
version. [Machine Information] tab first.
a When using Ver.3.5.2.1 or older ver- 2) Check every data for correctness.
sion (CD-ROM), the setting proce- a The figure shows the display of another
dure shall conform to that described model as an example.
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: SERVICE MATE
SMP-623)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826142000
4) Select [Data clear and Set up] from
[Select Function] item.
5) Click [OK] button to proceed to the setup
screen.
a Select a [Variation Code] from the fol-

lowing table.
3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
4 HD465-7R, HD605-7R
Setting with VHMS initial setting manual (tool) (*1)

PLM Card-type
payload Payload Date
VHMS function in meter (PLM)
controller VHMS meter Time
function Model Type Variation Time difference
controller (PLM- ) code (GMT)
Summer time
Not installed — Not installed Not installed — — — —
Not installed — Installed Installed — — — —
Installed Not installed Not installed Not installed ST

HD465 Set
Installed Not installed Installed Installed HD605 – 7R P2 properly
Installed Installed Not installed Installed PV
(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool)
a A variation code is an item among the model, date, etc. that are set with the personal computer software
for intial setting of the VHMS is initialized. It is used to notify the VHMS "whether the PLM in the VHMS
is effective (Code: PV), whether PLM II is connected (Code: P2), and whether the machine has the pay-
load 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.
HD465-7R, HD605-7R 5
4) When [Machine Information] information is [Communication Setting] [ORBCOM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
mation, press [OK] button.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTRY], employ the following
press [OK] button. procedure.
a ORBCOM installation specification 1] Select [SHORT FAULT HISTRY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
6 HD465-7R, HD605-7R
9) When modifying the setting of [SHORT

GCC codes and applicable regions
TREND ANALYSIS], employ the following
procedure. Code Applicable region Code Applicable region
1] Select [SHORT TREND ANALYSIS] 1 America 122 Korea
from the screen and then press [Edit] 120 Italy 123 Brazil
button in the lower left side of [File
121 Malaysia 130 Japan
Transfer Setting] block to display the
setup screen.
11) As every data in [Communication Setting]
2] Correct the setting and, as it is com-
has been checked and corrected, press
pleted, press [OK] button.
[Apply] button to settle the setting.
a In the initial setting, enter [20h] to
a As [Apply] button is pressed, a mes-
[SMR] and then set the function to
sage confirming above setting will
ON.
appear on the screen. Check the set-
ting again and, if the setting is correct,
press [OK] button.
10) When modifying the setting of [Satellite

Setting], employ the following procedure.
1] Press [Edit] button in the [Satellite
Setting] block to display the setup
screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
12) As every data in [Machine Information]
and [Communication Setting] has been
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].
HD465-7R, HD605-7R 7
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
8 HD465-7R, HD605-7R
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used select it
and, press [Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions
Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
HD465-7R, HD605-7R 9
11) Set the starting switch to OFF position.

Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
12) Opening station request of ORBCOMM

terminal
Fill in the necessary matters in the paper
of "Request for Orbcomm Terminal Activa-
tion" and send to Customer Support Gr.
Solution Div. komatsu Ltd by fax or mail.
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
7. Executing quick Pm 6) Press the buzzer cancel switch [U] to

a Quick Pm denotes the Pm click done by start the snapshot.
use of the manual snapshot function of the a As the snapshot is started, the upper
machine monitor. column starts displaying the elapsed
a It stores 7 minutes and 30 seconds worth time.
of data to VHMS controller. a [–] in the leftmost position of the lower
k Park the machine in a flat place. column is replaced with [*] for every
30 seconds. When two or more [*]
1) Start the engine. signs are displayed, the rightmost
2) Switch the machine monitor to Service one flashes.
menu. a When stopping the snapshot currently
a For the procedure of opening Service taking place, press the buzzer cancel
menu, see "Special functions of switch [t].
machine monitor".
3) Display the manual snapshot function
screen from the menu screen of Service
mode.
7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tem-
perature and torque converter oil tem-
4) Press the buzzer cancel switch [U]. perature are within the operating
5) [READY] will be displayed on the screen, range.
turning on the standby mode. a After 10th [*] is displayed (5 minutes
a The lower column displays 15 pieces elapsed from the start), [#] will be dis-
of [–] sign. played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
q #: Indicates the data sampling interval
is once every 1 second.
12 HD465-7R, HD605-7R
a Machine operation for snapshot

Measurement conditions
Start Finish Time Operation of machine AISS Power mode Parking Remarks
switch setting Shift lever brake Retarder Dump lever
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) Before setting the gearshift lever in the D position, return the engine speed to low idle temporarily (to prevent the
machine from running out).
HD465-7R, HD605-7R 13
8) As 7 minutes and 30 seconds elapsed 10) Open the quick Pm data to draw a graph.
from start of the snapshot, following a Set the Time to the X-axis and set the
screen appears and then the initial screen following to the Y-axis.
is restored in 5 seconds. (End of snap- q Engine Speed (Engine speed)
shot) q Fuel Inject (Fuel injection rate)
q Blowby Press (Blow-by pressure)
q F Exhaust Temp (Exhaust temperature
of No. 1, 2, 3 cylinders)
q R Exhaust Temp (Exhaust tempera-
ture of No. 4, 5, 6 cylinders)
q Engine Oil Press (Engine oil pres-
sure)
q Engine Oil Temp (Engine oil tempera-
ture)
q Coolant Temp (Engine coolant tem-
perature)
q Ambient Temp (Ambient temperature)
q Boost Press (Boost pressure)
q Accelerator Pos (Accelerator posi-
Important tion)
Data of quick Pm are recorded only once. q Hoist Lev Pos (Dump lever position)
Thus, if another quick PM is repeated, the cur- q T/C Oil Temp (Torque converter oil tem-
rent data will be overwritten with the last one. perature)
In order to avoid above trouble, be sure to q T/M Out speed (Transmission output
download data of every completed quick Pm to shaft speed)
PC. For the procedure, see 8. Download of q Shift Indicator (Gearshift position)
setting data. q Lock Up Signal (Lockup signal)
q Retarder Temp (Retarder oil tempera-
9) Analyze the quick PM data by use of the ture)
analysis tool. q F Brake Press (Front brake oil pres-
a For detailed usage of the analysis sure)
tool, see the operation and mainte- q R Brake Press (Rear brake oil pres-
nance manual. sure)
q Retarder Position (Retarder position)
q Foot Brake Position (Foot brake posi-
tion)
14 HD465-7R, HD605-7R
11) Apply a check mark to the "Graph value

display at click position".
HD465-7R, HD605-7R 15
12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
display – Not an actual one)
16 HD465-7R, HD605-7R
8. Download of setting data

1) Using harness N2, connect PC N3 to
download connector DPC7 in the cab or
ground download connector VDL.
a Download connector DPC7 in the cab

is installed to box (1) behind the cover
at the rear of the operator's seat.
2) When using download connector DPC7 in

the cab, set the starting switch to ON posi-
tion.
3) When using the ground download connec-
tor VDL, set switch (3) to ON position.
a The green LED will come on.
4) Click [VHMS analysis tool] icon on PC

screen, to start up the VHMS analysis
tool.
a Ground download connector VDL is

installed in box (2) at the rear of the
f r on t t ir e on t he l eft si d e o f th e
machine.
HD465-7R, HD605-7R 17
a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and a For the operating procedure, see the
maintenance manual. VHMS analysis tool operation and
maintenance manual.
a Check that [MFA0] code, which was
used in the quick snapshot, is indi-
cated in [Fault History].
a Check the snap shot data are re-
corded.
5) Using [Download] function, download the

data currently recorded on VHMS control-
ler to PC.
a For the operating procedure, see the
VHMS analysis tool operation and 2) As check of the setting data is finished,
maintenance manual. end [VHMS analysis tool].
a After confirming the download is com-
plete, proceed to the next step.
18 HD465-7R, HD605-7R
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, set the starting switch to
OFF position.
2) End the OS of PC N3 and then turn off the
PC power.
11. Report to Komatsu

As steps 1 – 10 are completed, send "VHMS/
WebCARE Basis Information Sheet" to VHMS/
WebCARE Support Center in Komatsu Head-
quarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
3) When the data was download was per- a In this case, send VHMS data via Notes
formed in the cab, disconnect harness N2 (LAN) or E-mail (WAN).
from download connector DPC7.
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
4) When ground download was performed,

set the switch (3) to OFF, and disconnect
N2 from download connector VDL.
HD465-7R, HD605-7R 19
[For storage] Date of setting:

DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Is model name identical with machine body? yes no

Initial setting of VHMS controller
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
20 HD465-7R, HD605-7R
[For storage] Date of setting:

DB/branch
ORBCOM Station Opening Work office name
Check Sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
VHMS controller serial No.
ORBCOM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
HD465-7R, HD605-7R 21
22 HD465-7R, HD605-7R
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1 or
older version)
a Testing instrument a This work is done inside the cab (from PC).
a Setting information in the current VHMS
controller is saved to the PC and the
1 799-608-3211 Diskette saved information is loaded to the new
2 799-608-3220 Wiring harness VHMS controller after the replacement.
N Note type PC 2-1. Confirmation and saving of VHMS controller
Commercially (Windows 98/2000/Me/XP setting information prior to replacement
3
available and terminal "RS232C" is 1) Connect the PC and start the VHMS initial
with it) setting tool.
a See the "VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure" for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the "VHMS initial setting work check
sheet".
a Information such as models shown in the fig-
ures may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a This work is done inside the cab (from PC). 3) Confirm every information before the
a Using [Download] function, download the replacement.
currently recorded and remained data on 4) Select [Save] from [File] of the menu.
VHMS to PC.
a For the operating procedure, refer to "8.
Download of setting data" in "VHMS con-
troller initial setting procedure".
HD465-7R, HD605-7R 23
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure" for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Select [Load] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end

the VHMS setting tool.
7) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
ler.
24 HD465-7R, HD605-7R
4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
HD465-7R, HD605-7R 25
9) The confirmation screen will ask whether 3. Confirmation, saving and loading of VHMS
or not the data before the above setup is controller setting information (Ver. 3. 5. 2. 1
to be saved. Press [NO] button. or later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information in the current VHMS
controller is saved to the PC and the saved
information is loaded to the new VHMS con-
troller after the replacement.
3-1. Confirmation of VHMS controller setting infor-

mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
3) Select [Save current setting before

replacement of VHMS controller] and
press [Next] button.
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
26 HD465-7R, HD605-7R
4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] but- ment of VHMS controller] and press [Next]
ton. button.
5) Select [Exit] from [File] of the menu to end 4) Currently saved information will be dis-
the VHMS initial setting tool. played. Press [Next] button.
6) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
5) Adjust the time and press [Apply] button.
HD465-7R, HD605-7R 27
6) The confirmation screen will ask whether [Operations needed after replacement of VHMS
or not the data before the above setup is controller]
to be saved. Press [NO] button. a Execute the quick Pm referring "7. Executing
a It is not necessary to save the data quick Pm" in "VHMS controller initial setting
before the setting. procedure".
a Download the data referring "8. Download of
setting data" in "VHMS controller initial setting
procedure".
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
7) The above completes modification of the E-mail: webcare@komatsu.co.jp

setting. Press [OK] button to end the
VHMS initial setting tool.
28 HD465-7R, HD605-7R
Pm Clinic check sheet 1
HD465-7R, HD605-7R 29
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31
Initial setting of payload meter 1

In the following cases, perform "setting of option selection of machine monitor" 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) (*1)

PLM Card-type
payload Payload Date
VHMS function in meter (PLM)
controller VHMS meter Variation Time
function Model Type Time difference
controller (PLM- ) code
(GMT)
Summer time
Not installed — Not installed Not installed — — — —
Not installed — Installed Installed — — — —
Installed Not installed Not installed Not installed ST
Installed Not installed Installed Installed HD465 – 7R P2 Set

HD605 properly
Installed Installed Not installed Installed PV
(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool)
When there is no problem in installation and wiring of the payload meter but there are the following prob-
lems, 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 loaded machine is stopped", "There are not the menus related
to the payload meter on the match monitor", etc.
a In the following cases, perform "setting of option selection of machine monitor" and "setting with
VHMS initialization manual (tool)" according to Table 1.
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 In the following cases, perform "setting of option selection of machine monitor" and "setting with
VHMS initialization manual (tool)" according to Table 1.
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.
32 HD465-7R, HD605-7R
Setting of payload meter built in VHMS 1

Outline of procedure
HD465-7R, HD605-7R 33
Set various items of the payload meter (PLM) with 3. Correction of calculation of load weight
the machine monitor. a Since this function affects the accuracy
1. Selection of service menu directly, execute the following procedure
While the service menu selection screen is dis- securely.
played, select the PLM setting function (PLM). a Be sure to measure the weight of the
empty machine and that of the fully loaded
machine as a set in order according to the
a The machine must travel for about 3 min-
utes each after its empty weight and its
fully loaded weight are measured.
Accordingly, secure a road for this pur-
pose.
a The relationship between the suspension
pressure and load weight corrected with
this function cannot be returned to the
condition at the time of shipment. Accord-
ingly, perform the following procedure very
carefully.
2. Setting of travel distance to recognize comple-
1) Measure the weight of the empty machine
tion of loading
with a weightmeter and record it (Write it
on a sheet of paper, etc.)
2) Input the measured weight of the empty
machine and drive the machine for about
3 minutes.
1] Select "EMPTY WEIGHT".
Input a travel distance to recognize completion

of loading by pressing the following buttons.
The setting range is 0 – 255 m (0.0 – 0.158
miles).
q [ > ] button: Number at cursor moves for-
ward
q [ < ] button: Number at cursor moves q [>], [<] buttons: Select "EMPTY
backward WEIGHT" or "LOADED WEIGHT"
q [U] button: Enter number at cursor q [U] button: Enter the selection
q [ t ] button: Stop inputting number q [t] button: Return to the previ-
a If the set value is too small, the system ous screen
may recognize that loading is completed If the weight of the empty machine
while the machine is still being loaded. has been input and the machine has
been driven for about 3 minutes,
side of WEIGHT.
(SHORT): short ton
34 HD465-7R, HD605-7R
2] Check that measurement of the 4] Check the input value.

weight of the empty machine has
been completed.
q [> ] button: Select "YES"

q [< ] button: Select "NO"
q [U] button: Check that measure- q [t] button: Enter
ment has been completed and 5] Move the machine to a place where
go to the next step you can drive it for about 3 minutes.
q [t] button: Return to the previ-
ous screen
3] Input the measured weight of the
empty machine.
q [U] button: After getting ready

for drive, press this button and
start driving the machine
q [t] button: Return to the value
q [>] button: Number at cursor inputting screen
moves forward Drive the machine for about 3 min-
q [<] button: Number at cursor utes at a speed higher than 8 km/h to
moves backward settle the relationship between the
q [U] button: Enter number at cur- weight of the machine and the sus-
sor pension pressure under that weight.
q [t] button: Return to the highest-
order digit position of the number
to input the value again. If this
button is pressed again, inputting
of the value is stopped and the
previous screen appears.
q Inputtable range
HD465-7R:
(metric ton)
HD605-7R:
(metric ton)
HD465-7R, HD605-7R 35
6] The progress of measurement is dis- 5) Input the measured weight of the fully
played. loaded machine and drive the machine for
about 3 minutes.
1] Select "LOADED WEIGHT".
For the method of displaying the fol-
lowing screen, see the steps up to the
above step.
q [t] button: Stop measurement

and return to the previous screen
As measurement is executed,
the number of "*" increases.
When measurement is finished,
the next screen appears auto- q [>], [<] buttons: Select "EMPTY
matically. WEIGHT" or "LOADED WEIGHT"
3) Load the machine to measure its fully q [U] button: Enter the selection
loaded weight. q [t] button: Return to the previ-
ous screen
If the weight of the empty machine
has been input and the machine has
been driven for about 3 minutes,
side of WEIGHT.
(SHORT): short ton
2] Check that measurement of the
weight of the fully loaded machine
has been completed.
q [t] button: Return to the menu screen
When loading is started, the menu
screen appears automatically. When
indicating the current load for refer-
ence while the machine is being
loaded, go out of "Service mode 1"
temporarily and return to "Display of
load weight/integrated odometer".
On this screen, you can check the
current load.
4) Measure the weight of the fully loaded
machine with a weightmeter and record it
(Write it on a sheet of paper, etc.)
q [U] button: Go to the next step

after confirming that measure-
ment has been completed.
q [t] button: Return to the previ-
ous screen
36 HD465-7R, HD605-7R
3] Input the measured weight of the fully 5] Move the machine to a place where
loaded machine. you can drive it for about 3 minutes.
q [>] button: Number at cursor q [U] button: After getting ready

moves forward for drive, press this button and
q [<] button: Number at cursor start driving the machine
moves backward q [t] button: Return to the screen
q [U] button: Enter number at cur- for inputting values
sor Drive the machine for about 3 min-
q [t] button: Return to the highest- utes at a speed higher than 8 km/h to
order digit of the number to input settle the relationship between the
the value again. If this button is weight of the machine and the sus-
pressed again, inputting of the pension pressure under that weight.
value is stopped and the previ- 6] The progress of measurement is dis-
ous screen appears. played.
a Inputtable range
HD465-7R:
A1 ± (A1 × 0.25) (metric ton)
Where,
A1 = {43.6 [t] (Operating weight)
+ 46 [t] (Max. payload)}
HD605-7R:
A2 ± (A2 × 0.25) (metric ton)
Where,
A2 = {46.8 [t] (Operating weight)
+ 63 [t] (Max. payload)}
4] Check the input value.
q [t] button: Stop measurement

and return to the previous screen
As measurement is executed, the
number of "*" increases. When mea-
surement is finished, the next screen
appears automatically.
q [< ] button: Select "YES"

q [> ] button: Select "NO"
q [t] button: Enter
HD465-7R, HD605-7R 37
7] Dump the load in the dump area. The current standard level value is
displayed on the upper line. The incli-
nometer value (F) at the current posi-
tion blinks. Enter it when it is
stabilized.
2] Turn the machine 180 degrees (Stop
it in the opposite direction).
3] Enter value of (R).
q [t] button: Return to the menu

screen
If the load is dumped with the dump
lever, the menu screen appears auto-
matically.
If the load is dumped normally, cor-
rection is finished.
Input a travel distance to recognize
4. Correction of level of inclinometer completion of loading by pressing the
1) Move the machine to a level place. following buttons.
2) Input the inclinometer reading (F) at the the setting range is 0 – 255 m (0.0 –
current position and that (R) after turning 0.158 mile).
the machine 180 degrees (stopping it in q [>] button: Number at cursor
the opposite direction) on the same posi- moves forward
tion and use the average value as the q [<] button: Number at cursor
standard level. moves backward
1] Enter value of (F). q [U] button: Enter the blinking
value
screen
q [U] button: Enter the blinking
value
screen
displayed on the upper line. The incli-
nometer value at the current position
blinks. Enter it when it is stabilized.
q [U] button: Enter the blinking

value
screen
38 HD465-7R, HD605-7R
4] Enter the standard level value. 6. Setting of load weight to recognize start of
loading
q [< ] button: Select "YES"

q [> ] button: Select "NO" Input a load weight to recognize start of load-
q [t] button: Enter ing by pressing the following buttons.
5. Setting of criterion of maximum travel speed ward
q [ < ] button: Number at cursor moves back-
ward
q [U] button: Enter number at cursor
q [ t] button: Stop inputting number
The setting range is 6 – 25.5% of the rated
load weight.
(Default: 15%)
a This function does not assure the opera-
tion because of the contrary phenomena
shown below.
q If the value is reduced, start of loading
may be recognized wrongly.
q If the value is increased and a loader hav-
ing a small-capacity bucket is used, the
Input a criterion of the maximum travel speed forecast function of the outside indicator
by pressing the following buttons. lamps and the MMS communication may
q [ > ] button: Number at cursor moves for- not operate normally.
ward
q [ < ] button: Number at cursor moves
7. Setting of indication range of outside indicator
backward
lamps
q [U] button: Enter number at cursor
q [t] button: Stop inputting number
The setting range is 0 – 99 km/h (0 – 62 MPH).
(Default: 99 km/h)
Input an indication range of the outside indica-

tor lamps by pressing the following buttons.
ward
HD465-7R, HD605-7R 39
q [ < ] button: Number at cursor moves back- q [>], [<] buttons: Select "WHEN
ward DUMPING" or "WHEN TRAVELING"
q [U] button: Enter number at cursor WHEN DUMPING (Setting at time of ship-
q [t] button: Stop inputting number ment)
a The setting range is 0 - 130% of the rated The load weight measured when the
load weight. dump lever is shifted from the "FLOAT"
Set A (Yellow lamp) higher than G (Green position to "another position" in the dump
lamp) and set R (Red lamp) higher than A area is saved.
(Yellow lamp). WHEN TRAVELING
The data sampled while traveling from the
8. Setting of OFFSET range loading area to the dump area is pro-
cessed statistically and the hauled load
weight is entered and saved when it is
dumped.
q [U] button: Enter the selected method
q [t ] button: Return to the menu screen
2) Enter the selected method.
Input an offset range by pressing the following

buttons.
ward
q [ < ] button: Number at cursor moves back-
ward
q [U] button: Enter number at cursor q [ <] button: Select "YES"
q [t] button: Stop inputting number q [ >] button: Select "NO"
a The setting range is -5.0 – +5.0 [t]. q [t ] button: Enter
Check the unit of the input value on the
previous menu screen.
a The unit is indicated in the ( ) on the right
side of the input value [t].
(SHORT): short ton
9. Selection of method of entering saved load

weight
1) Select the method of entering the saved
load weight.
40 HD465-7R, HD605-7R
Setting of card-type payload meter (PLM- ) after installation or replace-

ment 1
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.
q When card-type payload meter is installed for the first time

q 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.)

q Set the model selector switch (No. 4).
Position of rotary switch Model
2 HD465-7R Small size tire
7 HD465-7R Large size tire
A HD605-7R Large size tire
q Set weight unit setting switch (No. 7).
Position of switch Model
Upper Metric ton
Lower American ton (Short ton)
HD465-7R, HD605-7R 41
q Set buzzer volume switch (B) and switch forcible prohibition switch (No. 8), if necessary.
When changing setting of these switches from the initial positions, be sure to check with the
Operation and Maintenance Manual.
q Do not change the load weight correction trimmer (No. 1) from the initial position.
q 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 HD465-7R and HD605-7R, 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 indica-
tion.)
Optional setting
Transmis- Execution of
sion baud automatic
Option code Type of data communication
rate transmission Setting of Setting of
when dumping is finished
(bit/sec) 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
42 HD465-7R, HD605-7R
3. Method of changing option code setting

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

q MODE (2)
q LIGHT/INC (3)
q TOTAL/SFT (4)
q CAL/CLR (5)
Screen (6)
a While watching the screen, operate switches (2) – (5) to set values.
HD465-7R, HD605-7R 43
2) Display the option code screen according 3) Changing set value of option code
to the following procedure. a You can change the digit at the blink-
1] Press MODE switch (2) for 2 sec- ing place.
onds.
Display: Cd: dp (Cd lights up and dp q Changing ones digit
blinks)
2] Press MODE switch (2).

Display: A. CLE (A lights up and CLE
blinks)

Display: F. CHE (F. CHE blinks)

Display: d. XXX (d. XX lights up and
X at ones place blinks)
q XXX = Currently set machine ID
1] Press LIGHT/INC switch (3).
Display: OP: XX (OP: X lights up and
Displa:y 0. XXX (0. XX lights up and
q XX = Ones digit of currently set
q XXX = Currently set operator ID
option code is increased by 1.
q Changing tens digit
Display: SP: XX (SP: X lights up and
1] Press TOTAL/SFT switch (4).
q The blinking point moves to the
q XX = Current set limit speed
tens place.
(km/h)

q XX = Current set option code

X at tens place blinks)
q XX = Tens digit of currently set
option code is increased by 1.
44 HD465-7R, HD605-7R
q Changing place to be changed 6] Press CAL/CLR switch (5).

1] Press TOTAL/SFT switch (4). Display: P. SEL (P. SEL lights up)
q The blinking point moves to the
ones place. 7] Press CAL/CLR switch (5).
Display: H. SEL (H. SEL lights up)
8] Press CAL/CLR switch (5).

Display: E. SEL (E. SEL lights up)
9] Press TOTAL/SFT switch (4).

Display: A. XXX (A. lights up and
XXX blinks)
q XXX = Currently set display level
of external lamp 1

Display: b. XXX (b. lights up and XXX
4) Finishing setting blinks)
Press MODE switch (2). q XXX = Currently set display level
of external lamp 2
4. Setting threshold value of external indica-
tor lamp 11] Press CAL/CLR switch (5).
a When installing the card-type payload Display: c. XXX (c. lights up and XXX
meter to a machine having the 3-bulb blinks)
external indicator lamp (HD465-7R, q XXX = Currently set display level
HD605-7R), be sure to set the threshold of external lamp 3
value of the external indicator lamp.
1) Set the gearshift lever in "N" and the dump Display: c. XXX (c. lights up and XXX
lever in "FLOAT". blinks)
2) Set the threshold value of the external q XXX = Set to 050.
indicator lamp according to the following a If LIGHT/INC switch (3) is held,
procedure. XXX increases to 255 and then
a For the setting switches, see "2. Set- returns to 0.
t i ng o f o pt i on c o de " , M e th o d o f
changing option code. 13] Press CAL/CLR switch (5).
1] Press MODE switch (2) and LIGHT/ Display: d. XXX (d. lights up and XXX
INC switch (3) simultaneously for 3 blinks)
seconds. q XXX = Currently set display level
Display: CHEC (CHEC blinks) of external lamp 4
2] Press TOTAL/SFT switch (4) and 14] Press LIGHT/INC switch (3).
LIGHT/INC switch (3) simultaneously Display: d. XXX (d. lights up and XXX
for 2 seconds. blinks)
Display: S. SEL (S. SEL lights up) q XXX = Set to 090.
a If LIGHT/INC switch (3) is held,
3] Press CAL/CLR switch (5). XXX increases to 255 and then
Display: UP: XX (UP: lights up and returns to 0.
XX blinks)
4] Press CAL/CLR switch (5). Display: E. XXX (E. lights up and
Display: PL: XX (PL: lights up and XX XXX blinks)
blinks) q XXX = Currently set display level
of external lamp 5
Display: O. SEL (O. SEL lights up)
HD465-7R, HD605-7R 45

Display: E. XXX (E. lights up and
XXX blinks)
q XXX = Set to 105. (HD465-7R)
q XXX = Set to 100. (HD605-7R)
a If LIGHT/INC switch (3) is held,
XXX increases to 255 and then
returns to 0.

Display: CHEC (CHEC blinks)
18] Press MODE switch (2) and finish

setting.
5. Check of setting
For 30 seconds after the card-type payload
meter is turned ON, the model selection code,
setting of memory card using switch, setting of
clinometer using switch, setting of weight unit
setting switch, setting of switch forcible prohibi-
tion switch, and setting of option code are dis-
played. Check that they are correct.
a For contents of indication made when the
power is turned ON, see Operation and
Maintenance Manual, Handling of payload
meter (card type), Contents of indica-
tion.
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47

© 2007 KOMATSU
All Rights Reserved
48 HD465-7R, HD605-7R
SEN02717-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 13
HD465-7R, HD605-7R 1
SEN02717-00 40 Troubleshooting
Failure codes table 1

Failure Failure contents Applicable Action History Reference
codes equipment code classification manual
1500L0 Detection of double engagement TM E03 Mechanical
system
15B0NX Clogging of transmission oil filter TM E01 Mechanical
system
Mechanical
15F0KM Abuse 1 of gear shifting from reverse to forward TM — system
Mechanical
15F0MB Abuse 2 of gear shifting from reverse to forward TM — system
Mechanical
15F7KM Abuse of transmission forward clutch disk TM — system
15G0MW Trouble in reverse clutch system TM E03 Electrical
(command holding pressure, fill ON, detection of slip) system
15G7KM Abuse of transmission reverse clutch disk TM — Mechanical
system
15H0MW Trouble in high clutch system TM E03 Electrical
15J0MW Trouble in low clutch system TM E03 Electrical
Trouble in 1st clutch system Electrical
15K0MW (command holding pressure, fill ON, detection of slip) TM E03 system Troubleshooting
Trouble in 2nd clutch system Electrical by failure code,
15L0MW (command holding pressure, fill ON, detection of slip) TM E03 system Part 1
Trouble in 3rd clutch system Electrical SEN02533-00
15M0MW (command holding pressure, fill ON, detection of slip) TM E03 system
15N0MW Trouble in 4th clutch system TM E03 Electrical
15SBL1 Trouble I in reverse clutch pressure control valve TM E03 Electrical
(command OFF, fill ON) system
15SBMA Trouble II in reverse clutch pressure control valve TM E03 Electrical
(command holding pressure, fill OFF, detection of slip) system
Trouble I in high clutch pressure control valve Electrical
15SCL1 (command OFF, fill ON) TM E03 system
Trouble II in high clutch pressure control valve Electrical
15SCMA (command holding pressure, fill OFF, detection of slip) TM E03 system
Trouble I in low clutch pressure control valve Electrical
15SDL1 (command OFF, fill ON) TM E03 system
15SDMA Trouble II in low clutch pressure control valve TM E03 Electrical
15SEL1 Trouble I in 1st clutch pressure control valve TM E03 Electrical
15SEMA Trouble II in 1st clutch pressure control valve TM E03 Electrical
Trouble I in 2nd clutch pressure control valve Electrical
15SFL1 (command OFF, fill ON) TM E03 system
Trouble II in 2nd clutch pressure control valve Electrical
15SFMA (command holding pressure, fill OFF, detection of slip) TM E03 system
Trouble I in 3rd clutch pressure control valve Electrical
15SGL1 (command OFF, fill ON) TM E03 system
15SGMA Trouble II in 3rd clutch pressure control valve TM E03 Electrical Troubleshooting
(command holding pressure, fill OFF, detection of slip) system by failure code,
Trouble I in 4th clutch pressure control valve Electrical Part 2
15SHL1 TM E03 SEN02534-00
15SHMA Trouble II in 4th clutch pressure control valve TM E03 Electrical
Trouble II in lockup clutch pressure control valve Electrical
15SJMA (command holding pressure, detection of slip) TM E03 system
Electrical
2C4MNX Clogging of retarder cooling oil filter BK E01 system
2 HD465-7R, HD605-7R

2D05CA Wear of brake (rear right) BK E01 Mechanical
system
—
Mechanical
2D06CA Wear of brake (rear left) BK E01 system
Mechanical
2F00KM Dragging of parking brake TM — system
Mechanical
2G42ZG Lowering of accumulator oil pressure (front) TM E03 system
2G43ZG Lowering of accumulator oil pressure (rear) TM E03 Mechanical
system
6014NX Clogging of hydraulic oil filter BK E01 Mechanical
system
Operation of engine overrun prevention device Mechanical
989A00 (Note: Information is obtained from transmission con- MON E02 system
troller and failure code is displayed on monitor panel)
Inclination alarm (Raising body while machine is
inclined) (Note: Information is obtained from transmis- Mechanical
989D00 sion controller and failure code is displayed on moni- MON — system
tor panel)
Mechanical
A570NX Clogging of engine oil filter BK E01 system
Mechanical
AA10NX Clogging of air cleaner TM E01 system Troubleshooting
by failure code,
Electrical Part 2
AB00MA Trouble in battery charge circuit (No R-terminal signal) TM E03 system SEN02534-00
B@BAZG Lowering of engine oil pressure ENG E03 Mechanical
system
B@BAZK Lowering of engine oil level BK E01 Mechanical
system
B@BCNS Overheating of engine ENG E02 Mechanical
system
Mechanical
B@BCZK Low coolant level alarm TM E01 system
(B@BFZK) Lowering of fuel level MON — —
Mechanical
B@C7NS Overheating of brake cooling oil (rear) MON E02 system
B@CENS Overheating of torque converter oil MON E02 Mechanical
system
B@GAZK Lowering of battery electrolyte level BK E01 Mechanical
system
B@JANS Overheating of steering oil TM E02 Mechanical
system
Mechanical
B@HAZK Lowering hydraulic oil level BK E01 system —
Electrical
CA111 Abnormality in engine controller ENG E03 system
Electrical
CA115 Abnormality in engine Ne/Bkup speed sensor ENG E03 system
CA122 Abnormally high level of charge pressure sensor ENG E03 Electrical
system
CA123 Abnormally low level of charge pressure sensor ENG E03 Electrical
system Troubleshooting
CA131 Abnormally high level of throttle sensor ENG E03 Electrical by failure code,
system Part 3
Electrical SEN02535-00
CA132 Abnormally low level of throttle sensor ENG E03 system
Electrical
CA135 Abnormally high level of oil pressure sensor ENG E01 system
Electrical
CA141 Abnormally low level of oil pressure sensor ENG E01 system
CA144 Abnormally high level of coolant temperature sensor ENG E01 Electrical
system
HD465-7R, HD605-7R 3

CA145 Abnormally low level of coolant temperature sensor ENG E01 Electrical
system
Electrical
CA153 Abnormally high level of charge temperature sensor ENG E01 system
Electrical
CA154 Abnormally low level of charge temperature sensor ENG E01 system
Electrical
CA187 Abnormally low level of sensor power supply 2 ENG E03 system
CA212 Abnormally high level of engine oil temperature ENG E01 Electrical
sensor (for VHMS) system
CA213 Abnormally low level of engine oil temperature sensor ENG E01 Electrical
(for VHMS) system
CA221 Abnormally high level of ambient temperature sensor ENG E01 Electrical
system
Electrical
CA222 Abnormally low level of ambient temperature sensor ENG E01 system
Electrical
CA227 Abnormally high level of sensor power supply 2 ENG E03 system
Mechanical
CA234 Overspeed of engine ENG E02 system
Electrical
CA238 Abnormality in Ne speed sensor power supply ENG E03 system
CA263 Abnormally high level of fuel temperature sensor ENG E01 Electrical
system
CA265 Abnormally low level of fuel temperature sensor ENG E01 Electrical
CA271 Short circuit in PCV1 ENG E03 Electrical by failure code,
system Part 3
CA272 Disconnection in PCV1 ENG E03 system
Electrical
CA273 Short circuit in PCV2 ENG E03 system
Electrical
CA274 Disconnection in PCV2 ENG E03 system
CA322 Disconnection or short circuit in injector #1 system ENG E03 Electrical
system
system
system
Electrical
CA325 Disconnection or short circuit in injector #6 system ENG E03 system
Electrical
Electrical
CA342 Abnormality in matching of engine controller data ENG E03 Electrical
system
CA351 Abnormality in injector drive circuit ENG E03 Electrical
system
CA352 Abnormally low level of sensor power supply 1 ENG E03 Electrical
system
Electrical
CA386 Abnormally high level of sensor power supply 1 ENG E03 system
Electrical
CA431 Abnormality in idle validation switch ENG E01 system
Electrical Troubleshooting
CA432 Abnormality in idle validation setting ENG E03 system by failure code,
Electrical Part 4
CA441 Abnormally low level of source voltage ENG E03 SEN02536-00
system
CA442 Abnormally high level of source voltage ENG E03 Electrical
system
4 HD465-7R, HD605-7R

CA449 Abnormality 2 in common rail high pressure ENG E03 Electrical
system
Electrical
CA451 Abnormally high level of common rail pressure sensor ENG E03 system
Electrical
CA452 Abnormally low level of common rail pressure sensor ENG E03 system
Electrical
CA553 Abnormality 1 in common rail high pressure ENG E03 system
CA554 In-range trouble of common rail pressure sensor ENG E03 Electrical
system
CA559 Lowering 1 of supply pump pressure ENG E03 Electrical
system
CA689 Abnormality in engine Ne speed sensor ENG E03 Electrical
system
Electrical Troubleshooting
CA731 Abnormality in engine Bkup speed sensor phase ENG E03 system by failure code,
Electrical Part 4
CA757 Loss of all engine controller data ENG E03 system SEN02536-00
Electrical
CA778 Abnormality in engine Bkup speed sensor ENG E03 system
Electrical
CA1633 Abnormality in KOMNET ENG E03 system
CA2185 Abnormally high level of throttle sensor power supply ENG E03 Electrical
system
CA2186 Abnormally low level of throttle sensor power supply ENG E03 Electrical
system
CA2249 Lowering 2 of supply pump pressure ENG E03 Electrical
system
Electrical
CA2555 Abnormally low level of intake air heater relay voltage ENG E01 system
Electrical
CA2556 Abnormally high level of intake air heater relay voltage ENG E01 system
Electrical
D19HKB Trouble in stop lamp relay output system BK E01 system
D5ZKKZ Trouble in front brake cut valve system BK E01 Electrical
system
DAF9KM Wrong connection of connector MON E03 Electrical
system
(DAFRKR) Abnormality in CAN communication (monitor panel) TM — —
Electrical
DAQ0KK Lowering of source voltage TM E03 system
Electrical
DAQ0KT Abnormality in non-volatile memory TM E01 system
Electrical
DAQ2KK Trouble in solenoid power supply system TM E03 system
Troubleshooting
(DAQ9KQ) Disagreement of model selection signals MON E03 — by failure code,
(transmission controller) Part 5
SEN02537-00
DAQRKR Abnormality in CAN communication (transmission MON E03 Electrical
controller) system
(DAQRMA) Disagreement of option setting (transmission) MON E03 —
Electrical
DB10KT Abnormality in non-volatile memory BK E01 system
Electrical
DB12KK Trouble in solenoid power supply BK E03 system
Electrical
DB13KK Lowering of battery direct power supply voltage BK E03 system
(DB19KQ) Disagreement of model selection signals (brake) MON E03 —
DB1RKR Abnormality in CAN communication TM E03 Electrical
(retarder controller) system
(DB1RMA) Disagreement of option setting (brake) MON E03 —
HD465-7R, HD605-7R 5

DB2RKR Abnormality in CAN communication TM E03 Electrical
(engine controller) system
Electrical
DBBRKR Abnormality in CAN communication (VHMS) MON E01 system
Electrical
DBC2KK Trouble in solenoid power supply system ABS E03 system
Electrical
DBC3KK Lowering of battery direct power supply voltage ABS E03 system
(DBC9KQ) Disagreement of model selection signals (ABS) MON E03 —
DBCRKR Abnormality in CAN communication (ABS) TM E03 Electrical
system
(DBCRMA) Disagreement of option setting (ABS) MON E03 —
Electrical
DDD7KX Trouble in travel speed setting switch system BK E03 system
Electrical
DDD8KA Disconnection in ARSC system switch BK E03 system
Electrical
DDD8KB Short circuit in ARSC system switch BK E03 system
Electrical
DDD9KA Disconnection in ABS system switch ABS E03 system
DDD9KB Short circuit in ABS system switch ABS E03 Electrical
system
DDDAKA Disconnection in ASR system switch BK E01 Electrical
system
DDDAKB Short circuit in ASR system switch BK E01 Electrical
Electrical by failure code,
DDP6L4 Trouble in service brake pressure switch ABS E03 system Part 5
SEN02537-00
Trouble in high clutch flow sensor valve Electrical
DDTHKA (command holding pressure, fill OFF, no slip) TM E03 system
Trouble in low clutch flow sensor valve Electrical
DDTJKA (command holding pressure, fill OFF, no slip) TM E03 system
DDTKKA Trouble in 1st clutch flow sensor valve TM E03 Electrical
(command holding pressure, fill OFF, no slip) system
DDTLKA Trouble in 2nd clutch flow sensor valve TM E03 Electrical
DDTMKA Trouble in 3rd clutch flow sensor valve TM E03 Electrical
Trouble in reverse clutch flow sensor valve Electrical
DDTNKA (command holding pressure, fill OFF, no slip) TM E03 system
Trouble in 4th clutch flow sensor valve Electrical
DDTPKA (command holding pressure, fill OFF, no slip) TM E03 system
Electrical
DF10KA Input of no lever signal TM E03 system
DF10KB Input of multiple lever signal TM E03 Electrical
system
DGF1KX Transmission oil temperature sensor input signal out TM E03 Electrical
of range system
DGR2KZ Trouble in retarder oil temperature sensor (rear wheel) BK E01 Electrical
system (ground fault) system
Electrical
DGR6KX Steering oil temperature signal out of range TM E01 system
Torque converter oil temperature sensor input signal Electrical
DGT1KX out of range TM E01 system
VHMS
DHP4KY Short circuit in suspension pressure sensor system (indication: E01 Electrical
(front right) system Troubleshooting
PLM) by failure code,
VHMS Part 6
Disconnection or ground fault in suspension pressure Electrical SEN02538-00
DHP4KZ sensor system (front right) (indication: E01 system
PLM)
6 HD465-7R, HD605-7R

Short circuit in suspension pressure sensor system VHMS Electrical
DHP5KY (front left) (indication: E01 system
PLM)
VHMS
DHP5KZ Disconnection or ground fault in suspension pressure (indication: E01 Electrical
sensor system (front left) PLM) system
Trouble in suspension pressure sensor system Electrical
DHP6KA (rear right) BK E01 system
DHP6KX (rear right) BK E03 system
Short circuit in suspension pressure sensor system VHMS Electrical
DHP6KY (rear right) (indication: E01 system
PLM)
Disconnection or ground fault in suspension pressure VHMS Electrical
DHP6KZ sensor system (rear right) (indication: E01 system
PLM)
DHP7KA Trouble in suspension pressure sensor system BK E01 Electrical
(rear left) system
DHP7KX BK E03
(rear left) system
VHMS
DHP7KY Short circuit in suspension pressure sensor system (indication: E01 Electrical
(rear left) PLM) system
VHMS
DHP7KZ Disconnection or ground fault in suspension pressure (indication: E01 Electrical
sensor system (rear left) PLM) system
Disconnection, ground fault or hot short in torque Electrical
DHT5KX converter inlet oil pressure sensor TM E01 system
DHT5L6 Trouble in torque converter inlet oil pressure sensor TM E01 Electrical
system
DHU2KX Trouble in accumulator oil pressure sensor (front) TM E01 Electrical Troubleshooting
system by failure code,
Electrical Part 6
DHU3KX Trouble in accumulator oil pressure sensor (rear) TM E01 SEN02538-00
system
Trouble in ABS control valve pressure sensor Electrical
DHU6KX (front right) ABS E03 system
DHU7KX (front left) ABS E03 system
DHU8KX (rear right) ABS E03 system
DHU9KX Trouble in ABS control valve pressure sensor ABS E03 Electrical
(rear left) system
DJF1KA Disconnection in fuel level sensor system TM E01 Electrical
system
DK30KX Trouble in steering angle potentiometer BK E01 Electrical
system
Electrical
DK51L5 Trouble in manual retarder potentiometer and RVS BK E03 system
Electrical
DK52KX Trouble 1 in hoist lever potentiometer sensor BK E03 system
Electrical
DK53L8 Trouble 2 in hoist lever potentiometer sensor BK E03 system
DK54KX Trouble in boom positioner sensor BK E03 Electrical
system
DKD0L6 Trouble in steering speed sensor BK E01 Electrical
system
DKH0KX Inclinometer sensor signal out of range TM E01 Electrical
system
VHMS
DKH1KX Abnormality in inclinometer (indication: E01 Electrical
PLM) system
Disconnection in transmission input shaft speed Electrical
DLF1KA sensor system TM E03 system
HD465-7R, HD605-7R 7

DLF1LC Trouble in transmission input shaft speed sensor TM E03 Electrical
Disconnection in transmission intermediate shaft Electrical by failure code,
DLF2KA speed sensor system TM E03 system Part 6
Trouble in transmission intermediate shaft speed Electrical SEN02538-00
DLF2LC sensor TM E03 system
Electrical
DLF6KA Disconnection in wheel speed sensor (front right) ABS E03 system
DLF6L3 Trouble in wheel speed sensor (front right) ABS E03 Electrical
system
DLF7KA Disconnection in wheel speed sensor (front left) ABS E03 Electrical
system
DLF7L3 Trouble in wheel speed sensor (front left) ABS E03 Electrical
system
Electrical
DLF8KA Disconnection in wheel speed sensor (rear right) BK E01 system
Electrical
DLF8L3 Trouble in wheel speed sensor (rear right) ABS E03 system
Electrical
DLF8LC Trouble in wheel speed sensor system (rear right) BK E01 system
Electrical
DLF8MA Disconnection in wheel speed sensor (rear right) ABS E03 system
DLF9KA Disconnection in wheel speed sensor (rear left) BK E01 Electrical
system
DLF9L3 Trouble in wheel speed sensor (rear left) ABS E03 Electrical
system
DLF9LC Trouble in wheel speed sensor system (rear left) BK E01 Electrical
system
Electrical
DLF9MA Disconnection in wheel speed sensor (rear left) ABS E03 system
Disconnection in transmission output shaft speed Electrical
DLT3KA sensor system TM E03 system Troubleshooting
DLT3LC Trouble in transmission output shaft sensor BK E01 system Part 7
Disconnection in transmission output shaft speed Electrical SEN02539-00
DLT4KA BK E01
sensor system
DLT4MA Disconnection in transmission output shaft speed BK E03 Electrical
sensor system
DV00KB Short circuit in buzzer output MON E01 Electrical
system
Electrical
DW2AKA Disconnection in main pressure variable valve output TM E01 system
Ground fault in main pressure variable valve output Electrical
DW2AKB circuit TM E01 system
Electrical
DW2AKY Hot short in main pressure variable valve output circuit TM E01 system
DW2AL1 Defective reset of main pressure variable valve TM E01 Electrical
system
DW2ALH Malfunction of main pressure variable valve TM E01 Electrical
system
DW35KZ Trouble in auto-suspension solenoid 1 output system BK E01 Electrical
(disconnection or ground fault) system
Trouble in auto-suspension solenoid 2 output system Electrical
DW36KZ (disconnection or ground fault) BK E01 system
Trouble in kick-out solenoid output system Electrical
DW72KZ (disconnection or ground fault) BK E01 system
Trouble (disconnection or ground fault) in hoist selec- Electrical
DW73KZ tor valve output system (disconnection or ground fault) BK E03 system
DW78KZ Trouble in BCV output system BK E01 Electrical
system
8 HD465-7R, HD605-7R

DWNBK4 Trouble in ASR shut-off valve (valve keeps operating) BK E01 Electrical
system
Electrical
DWNBKA Disconnection in ASR shut-off valve output circuit BK E01 system
Electrical
DWNBKB Ground fault in ASR shut-off valve output circuit BK E01 system
Electrical
DWNBKY Short circuit in ASR shut-off valve output circuit BK E01 system Troubleshooting
DWNBMA Trouble in ASR shut-off valve (valve does not operate) BK E01 Electrical by failure code,
system Part 7
DWNDKZ Trouble in ABS cut valve (front) system ABS E03
system
DWNDMA Defective ABS cut valve (front) ABS E03 Electrical
system
Electrical
DWNEKZ Trouble in ABS cut valve (rear) system ABS E03 system
Electrical
DWNEMA Defective ABS cut valve (rear) ABS E03 system
Trouble in rear wheel proportional pressure reducing Electrical
DX11K4 solenoid valve (valve keeps operating) BK E03 system
Disconnection in rear wheel proportional pressure Electrical
DX11KA reducing solenoid valve output circuit BK E03 system
DX11KB Ground fault in rear wheel proportional pressure BK E03 Electrical
reducing solenoid valve output circuit system
DX11KY Short circuit in rear wheel proportional pressure BK E03 Electrical
reducing solenoid valve output circuit system
DX11MA Trouble in rear wheel proportional pressure reducing BK E03 Electrical
solenoid valve (valve does not operate) system
Electrical
DX13KA Disconnection in hoist EPC valve output circuit BK E03 system
Electrical
DX13KB Ground fault in hoist EPC valve output circuit BK E03 system
Electrical
DX13KY Short circuit in hoist EPC valve output circuit BK E03 system
DX17K4 Trouble in ASR proportional pressure reducing BK E01 Electrical
solenoid valve (right) (valve keeps operating) system
DX17KA Disconnection in ASR proportional pressure reducing BK E01 Electrical
solenoid valve (right) output circuit system Troubleshooting
DX17KB Ground fault in ASR proportional pressure reducing BK E01 Electrical by failure code,
solenoid valve (right) output circuit system Part 8
Short circuit in ASR proportional pressure reducing Electrical SEN02540-00
DX17KY solenoid valve (right) output circuit BK E01 system
Trouble in ASR proportional pressure reducing Electrical
DX17MA solenoid valve (right) (valve does not operate) BK E01 system
DX18K4 solenoid valve (left) (valve keeps operating) BK E01 system
DX18KA Disconnection in ASR proportional pressure reducing BK E01 Electrical
solenoid valve (left) output circuit system
DX18KB Ground fault in ASR proportional pressure reducing BK E01 Electrical
DX18KY Short circuit in ASR proportional pressure reducing BK E01 Electrical
DX18MA solenoid valve (left) (valve does not operate) BK E01 system
Disconnection in ABS control valve (front right) output Electrical
DX21KA circuit ABS E03 system
Ground fault in ABS control valve (front right) output Electrical
DX21KB circuit ABS E03 system
DX21KY Short circuit in ABS control valve (front right) output ABS E03 Electrical
circuit system
HD465-7R, HD605-7R 9

DX21MA Defective ABS control valve (front right) ABS E03 Electrical
system
Disconnection in ABS control valve (front left) output Electrical
Ground fault in ABS control valve (front left) output Electrical
Short circuit in ABS control valve (front left) output Electrical
DX22KY circuit ABS E03 system
DX22MA Defective ABS control valve (front left) ABS E03 Electrical
system
DX23KA Disconnection in ABS control valve (rear right) output ABS E03 Electrical
circuit system
DX23KB Ground fault in ABS control valve (rear right) output ABS E03 Electrical
circuit system Troubleshooting
Short circuit in ABS control valve (rear right) output Electrical by failure code,
DX23KY circuit ABS E03 system Part 8
DX23MA Defective ABS control valve (rear right) ABS E03 system
Disconnection in ABS control valve (rear left) output Electrical
Ground fault in ABS control valve (rear left) output Electrical
DX24KY Short circuit in ABS control valve (rear left) output ABS E03 Electrical
circuit system
DX24MA Defective ABS control valve (rear left) ABS E03 Electrical
system
DX25MA Defective ABS front wheel system control valve ABS E03 Electrical
system
Electrical
DX26MA Defective ABS rear wheel system control valve ABS E03 system
Electrical
DXH1KA Disconnection in lockup clutch solenoid output circuit TM E03 system
Electrical
DXH1KB Ground fault in lockup solenoid output circuit TM E03 system
DXH1KY Hot short in lockup clutch solenoid output circuit TM E03 Electrical
system
DXH2KA Disconnection in high clutch solenoid output circuit TM E03 Electrical
system
DXH2KB Ground fault in high clutch solenoid output circuit TM E03 Electrical
system
Electrical
DXH2KY Hot short in high clutch solenoid output circuit TM E03 system
Electrical
DXH3KA Disconnection in low clutch solenoid output circuit TM E03 system Troubleshooting
DXH3KB Ground fault in low clutch solenoid output circuit TM E03 system Part 9
DXH3KY Hot short in low clutch solenoid output circuit TM E03
system
DXH4KA Disconnection in 1st clutch solenoid output circuit TM E03 Electrical
system
DXH4KB Ground fault in 1st clutch solenoid output circuit TM E03 Electrical
system
Electrical
DXH4KY Hot short in 1st clutch solenoid output circuit TM E03 system
Electrical
DXH5KA Disconnection in 2nd clutch solenoid output circuit TM E03 system
Electrical
DXH5KB Ground fault in 2nd clutch solenoid output circuit TM E03 system
DXH5KY Hot short in 2nd clutch solenoid output circuit TM E03 Electrical
system
10 HD465-7R, HD605-7R

DXH6KA Disconnection in 3rd clutch solenoid output circuit TM E03 Electrical
system
Electrical
DXH6KB Ground fault in 3rd clutch solenoid output circuit TM E03 system
Electrical
DXH6KY Hot short in 3rd clutch solenoid output circuit TM E03 system
Electrical
DXH7KA Disconnection in reverse clutch solenoid output circuit TM E03 system Troubleshooting
DXH7KB Ground fault in reverse clutch solenoid output circuit TM E03 Electrical by failure code,
system Part 9
DXH7KY Hot short in reverse clutch solenoid output circuit TM E03
system
DXHHKA Disconnection in 4th clutch solenoid output circuit TM E03 Electrical
system
Electrical
DXHHKB Ground fault in 4th clutch solenoid output circuit TM E03 system
Electrical
DXHHKY Hot short in 4th clutch solenoid output circuit TM E03 system
HD465-7R, HD605-7R 11
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
ABS : ABS controller system
VHMS : PLM function system of VHMS controller (Note: Displayed as "PLM" on machine monitor)
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note : Optional equipment is also included in this table.
1
12 HD465-7R, HD605-7R
Fuse locations 1
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breaker (30A/80A) and fuse locations in battery box and connection table
a This connection table shows the devices to which each power supply of the circuit breakers and fuse
box supplies power (An accessory power supply is a device which supplies power while the starting
switch is in the ON position and an unswitched power supply is a device which supplies power while the
starting switch is in the OFF and ON positions).
Circuit breaker Circuit breaker

Type of power supply Destination of power
No. capacity
Fuse box (BT2) *1

Unswitched FuA1 30A
power supply Fuse box (BT3) *1
(Battery output)
FuA2 30A Fuse box (BT3) *1
Fuse box (BT1) *1
FuB1 80A Fuse box (BT2) *1

Accessory
power supply Fuse box (BT4) *1
(Battery relay output)
Fuse box (BT3) *1
FuB2 80A
Fuse box (BT4) *1
Type of power supply Fuse No. Fuse capacity Destination of power
Emergency steering switch connected through fuse box

Unswitched power supply E.S/TF 10A
(BT2)
(Battery output)
EPP 10A Electric priming pump
Accessory power supply Intake air heater (engine) connected through heater relay
INH 120A
(Battery relay output) (HR)
*1: For fuse boxes (BT1) – (BT4), see the following pages.
HD465-7R, HD605-7R 13
Fuse box (BT1) location and connection table
a The circled numbers are the terminal numbers shown in the circuit diagram of each failure code.
q Fuse box BT1
Type of power Circuit breaker

Fuse No. Fuse capacity Destination of power
supply output
(1) 10A Main lamp and small lamp
(2) 10A Turn signal lamp
(3) 20A Headlamp (Low)
(4) 20A Headlamp (High)
Accessory FuB1 (5) 20A Headlamp (Low) *1

power supply (80A) (6) 20A Headlamp (High) *1
(7) 10A Brake lamp
(8) 20A Backup lamp
(9) 10A Small lamp *1
(10) 20A VHMS controller
*1: These are connected to the corresponding fuses (1), (3) and (4) and lighting switch and then connected
to the fuses again. See troubleshooting of electrical system (E mode), "E-12".
14 HD465-7R, HD605-7R
q Fuse box BT2

supply output
Key switch
(11) 10A Machine monitor, payload meter/controller
(ACC)
Key switch (12) 10A Rear view range monitor (if equipped), VHMS download
(BR) (13) 10A Parking brake circuit
(14) 20A Power window (Left)

Accessory
FuB1 (80A) (15) 20A Power window (Right)
power supply
(16) 10A Payload meter/controller
Unswitched
FuA2 (30A) (17) 10A Horn
power supply
Accessory
FuB1 (80A) (18) 10A Machine monitor
power supply
(19) 10A Transmission controller
(20) 20A Terminal B
(21) 10A Retarder controller, ABS controller

Unswitched
FuA2 (30A) (22) 20A Hazard lamp
power supply
(23) 10A Emergency steering
(24) 10A Room lamp, radio
(25) 10A Machine monitor, VHMS controller
HD465-7R, HD605-7R 15
q Fuse box BT3

supply output
Accessory
FuB1 (80A) (26) 20A Fog lamp (if equipped)
power supply
(27) 20A Air conditioner controller
(28) 20A Heater (if equipped)
(29) 20A Heater (if equipped)
Accessory (30) 20A ABS controller

FuB2 (80A)
power supply (31) 20A Retarder controller
(32) 10A Transmission controller, gearshift lever power supply
(33) 10A Emergency steering, parking brake relay
(34) 10A Radio
Key switch
(35) 5A Engine controller
(ACC)
Unswitched
FuA1 (80A) (36) 30A Engine controller
power supply
(37)
Unswitched
FuA1 (80A) (38) 30A Engine controller
power supply
(39)
(40) 2A Spare
16 HD465-7R, HD605-7R
q Fuse box BT4

supply output
(41) 10A Room lamp
Accessory (42) 10A Engine preheater power supply

FuB2 (80A)
power supply (43) 20A Yellow rotary lamp (if equipped)
(44) 20A Side lamp (if equipped)
Electrical operator's seat heater (if equipped), air

(45) 20A
suspension seat (if equipped)
(46) 10A External indicator lamp of payload meter

Accessory (47) 10A Tachograph (if equipped), cigarette lighter
FuB1 (80A)
power supply
(48) 20A Air conditioner
(49) 20A Spare
(50) 20A Front windshield wiper
HD465-7R, HD605-7R 17

© 2007 KOMATSU
All Rights Reserved
18 HD465-7R, HD605-7R
SEN02718-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 6
Connection table for connector pin numbers .................................................................................................. 8
T-adapter box and T-adapter table................................................................................................................ 37
HD465-7R, HD605-7R 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 testing 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 pre-
vent 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 symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting, 5. Troubleshooting
it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting tion in Items 2 – 4 to narrow down the causes
in accordance with the fixed procedure. of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
of the the failure exactly.
1) Have any other problems occurred apart
a The basic procedure for troubleshooting is
from the problem that has been reported?
as follows.
2) Was there anything strange about the
1] Start from the simple points.
machine before the failure occurred?
2] Start from the most likely points.
3) Did the failure occur suddenly, or were
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure 6. Measures to remove root cause of failure
occur? Even if the failure is repaired, if the root cause
5) Had any repairs been carried out before of the failure is not repaired, the same failure
the failure? When were these repairs car- will occur again.To prevent this, always investi-
ried out? gate why the problem occurred. Then, remove
6) Has the same kind of failure occurred the root cause.
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 HD465-7R, HD605-7R
Sequence of events in troubleshooting 1
HD465-7R, HD605-7R 3
Check before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean and drain
3. Check of fuel filter — Replace
4. Check of level and type of hydraulic oil — Add oil
5. Check of hydraulic oil strainer — Clean and drain
6. Check of hydraulic oil filter — Replace
Lubricating 7. Check of level and type of oil in engine oil pan — Add oil
oil/Coolant 8. Check of engine oil filter — Replace
9. Check of coolant level — Add coolant
10. Check of dust indicator for clogging — Clean and replalce
11. Check of power train oil filter — Replace
12. Check of powertrain oil level — Add oil
13. Check of final draive oil level — Add oil
14. Check of differential oil level — Add oil
1. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
2. Check of alternator terminal cables for looseness
Electrical — Retighten or replace
and corrosion
parts
3. Check of starting motor terminal cables for loose-
— Retighten or replace
ness and corrosion
4. Check of operation of instruments — Repair or replace
Hydraulic/ 1. Check for abnormal noise and smell — Repair

Mechanical 2. Check for oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 26 V Replace
2. Check of battery electrolyte level — Retighten or replace
3. Check wires for discoloration, burn, and removal
— Replace
of cover
4. Check for removed wire clamp and drooping wire — Repair
5. Check wiring for wetting with water
Electrical Disconnect and dry
(Check connectors and terminals for wetting with —
equipment connectors
water, in particular)
6. Check of slow-blow fuses and fuses for discon-
— Replace
nection and corrosion
7. Check of alternator voltage After several-minute
Replace
(with engine at medium speed or higher) operation: 27.5 – 29.5 V
8. Check of operating sound of battery relay
— Replace
(Starting switch OFF ON)
4 HD465-7R, HD605-7R
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
HD465-7R, HD605-7R 5
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Machine Names of the failure symptoms displayed in the failure history
Machine monitor Trouble
monitor on the machine monitor
display
display
Contents of
State where the machine monitor or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the machine monitor or control-
machine moni-
ler detects a trouble
tor or controller
Problem that
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
appears on
or controller
machine
Related
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value when normal required to judge the possi-
ble cause
• Remarks required to judge whether any cause is right or
1 not
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring har-
ness is disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes
into contact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply
2 (24V) circuit comes into contact with the electric power
supply (24V) circuit.
• Short circuit
Possible causes Cause by which a trouble is A harness abnormally comes into contact with a harness
and standard assumed to be detected of separate circuit.
value in normal (The order number indicates
state a serial number, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling T-
adapter
For troubleshooting, insert or connect the T- adapter as
3 described below unless especially specified.
• When “male“or “female“ is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
adapter in both the male and female.
• When “male“or “female“ is indicated for a connector
number, disconnect the connector, and insert the T-
adapter in only either the male or female.
(2) Pin number description sequence and tester lead han-
dling
For troubleshooting, connect the plus (+) and minus (-)
leads of the tester as described below unless especially
4 specified.
• Connect the plus (+) lead to a pin number or harness
indicated in the front.
• Connect the minus (-) lead to a pin number or harness
indicated in the rear.
6 HD465-7R, HD605-7R
Circuit diagram related
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• Connector No.: Indicates (Model - Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
HD465-7R, HD605-7R 7
Connection table for connector pin numbers 1

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.
8 HD465-7R, HD605-7R
HD465-7R, HD605-7R 9
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
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HD465-7R, HD605-7R 13
14 HD465-7R, HD605-7R
HD465-7R, HD605-7R 15
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
22 HD465-7R, HD605-7R
HD465-7R, HD605-7R 23
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
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HD465-7R, HD605-7R 31
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HD465-7R, HD605-7R 35
36 HD465-7R, HD605-7R
T-adapter box and T-adapter table 1

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identifica-
Part No. Part name
tion symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37
799-601-3200 T-box (for MS) 37
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
HD465-7R, HD605-7R 37
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identifica-
Part No. Part name
tion symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
38 HD465-7R, HD605-7R
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identifica-
Part No. Part name
tion symbol

799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for DT/HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q q
Adapter for engine (CRI-T3) PFUEL
799-601-9430 2 P q q
Adapter for engine (CRI-T3) PCV
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 Adapter for engine (CRI-T3) 2 C q q
Temperature sensor
Adapter for engine (HPI-T2)
795-799-5540 2 A q q
Adapter for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190 3 1,2,3L q q
Commonrail pressure
799-601-4230 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240 Adapter for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250 Adapter for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330 Adapter for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340 2 2,PA q q
Pump actuator
799-601-9020 Adapter for engine (CRI-T3) Injector 2 DT2 q q
799-601-9040 Adapter for engine (CRI-T3) SEGR, SBP 4 DT4 q q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
HD465-7R, HD605-7R 39

© 2007 KOMATSU
All Rights Reserved
40 HD465-7R, HD605-7R
SEN02533-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Troubleshooting by failure code, Part 1
Failure code [1500L0] (Dual engagement) ..................................................................................................... 3
Failure code [15B0NX] (Transmission oil filter: Clogging)............................................................................... 4
Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation) .......................................................... 6
Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) .......................................................... 6
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)..................................... 7
Failure code [15G0MW] (R clutch: Slipping)................................................................................................... 8
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting).................................. 10
Failure code [15H0MW] (Hi clutch: Slipping) ................................................................................................ 12
Failure code [15J0MW] (Lo clutch: Slipping) ................................................................................................ 14
Failure code [15K0MW] (1st clutch: Slipping) ............................................................................................... 16
Failure code [15L0MW] (2nd clutch: Slipping) .............................................................................................. 18
Failure code [15M0MW] (3rd clutch: Slipping) .............................................................................................. 20
Failure code [15N0MW] (4th clutch: Slipping)............................................................................................... 22
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) ...................... 24
Failure code [15SBMA] (R clutch solenoid: Malfunction).............................................................................. 26
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) ..................... 28
HD465-7R, HD605-7R 1
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ............................................................................. 32

Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)..................... 34
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) ............................................................................ 38
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) .................... 40
Failure code [15SEMA] (1st clutch solenoid: Malfunction)............................................................................ 44
2 HD465-7R, HD605-7R
Failure code [1500L0] (Dual engagement) 1

Action code Failure code Dual engagement
Trouble
E03 1500L0 (Transmission controller system)
Contents of
• Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
trouble
Action of • Suddenly shifts to Neutral while traveling, and cannot move off again.
controller • Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
appears on • The gear speed is shifted to Neutral.
machine
Related
• Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
information

Clutch pressure control valve
1 system failure code (15S*L1) Troubleshooting by the active failure code.
Possible causes has occurred
and standard
value in normal Defective hydraulic or
Clutch ECMV may be malfunctioning. Carry out trouble-
state 2 mechanical system of
shooting of hydraulic and mechanical systems.
clutch ECMV
Defective transmission
3 Troubleshooting by the active failure code.
controller
HD465-7R, HD605-7R 3
Failure code [15B0NX] (Transmission oil filter: Clogging) 1

Action code Failure code Transmission oil filter: Clogging
Trouble
E01 15B0NX (Transmission controller system)
Contents of • When the torque converter oil temperature is above 50°C, the signal circuit of the transmission
trouble clogging sensor is opened (disconnected from GND).
Action of
• None in particular.
controller
Problem that
appears on • If the machine is used without repairing, dust may enter the transmission circuit.
machine
• This failure can be checked in the monitoring function (Code: 40905). (Bit [1], normal: 0, clogging: 1)
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
1 • Clean or replace.
filter
1) Turn the starting switch OFF.
2) Disconnect connector TMF1.
3) Connect T-adapter.
Defective transmission filter
2 Resis-
clogging sensor Filter is normal Max. 1 z
Between TMF1 tance
(male) (1) – (2) Resis-
Filter is clogged Min. 1 Mz
tance
Possible causes 1) Turn the starting switch OFF.

and standard 2) Disconnect connectors ATC1 and TMF1.
Disconnection in wiring 3) Connect T-adapter.
value in normal
harness
state 3 Wiring harness between ATC1 (female) (17) Resis-
(Disconnection or defective Max. 1 z
– TMF1 (female) (1) tance
contact)
Wiring harness between TMF1 (female) (2) Resis-
Max. 1 z
– ground tance
2) Disconnect connectors ATC1.
3) Insert T-adapter.
Defective transmission con- 4) Connect conector.
4 5) Turn the starting switch ON.
troller
Between ATC1 Filter is normal Voltage Max. 1V
(female) (17) –
ground Filter is clogged Voltage 20 – 30 V
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation) 1

Action code Failure code R o F shifting abuse 1: Mistake in operation
Trouble
— 15F0KM (Transmission controller system)
Contents of • When output shaft speed is 200 – 300 rpm (about 5 – 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
• Non in particular.
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
machine • Only recorded in failure history.
Related
• Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal A forward-reverse shifting should be performed when the machine
1 Abuse
state is stationary. (Teach the proper operating method.)
Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) 1

Action
Failure code R o F shifting abuse 2: Mistake in operation
code Trouble
(Transmission controller system)
— 15F0MB
Contents of • When output shaft speed is above 300 rpm (about 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
Related
• Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information

and standard
1 Abuse
6 HD465-7R, HD605-7R
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation

or setting) 1
Action code Failure code Forward clutch disc abuse: Mistake in operation or setting
Trouble
— 15F7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
HD465-7R, HD605-7R 7
Failure code [15G0MW] (R clutch: Slipping) 1

Action code Failure code R clutch: Slipping
(R command is holding pressure, R clutch, fill switch is ON, and
Trouble
E03 15G0MW slipping detected)
• When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmis-
Contents of
sion input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission out-
trouble
put shaft speed sensor is abnormal.
Action of • Sets gear in neutral.
controller • Turns lockup system OFF.
• Machine cannot travel in reverse.
• If gearshift lever is set in neutral, machine cannot start.
• Operator can move machine by following escape procedure.
Problem that 1) Stop travel and set gearshift lever in N position.
appears on 2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
machine other to set machine in emergency escape mode.
3) Operate gearshift lever and start machine again.
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – L or from N to R.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
• Electric current of out put to ECMV can be checked with monitoring function (Code: 31606 (mA)).
• If electrical system is normal, check reverse clutch and mechanical/hydraulic system of pressure
Related
control valve for defect.
information
• When carrying out emergency escape operation, see "Emergency escape method when electrical
system has trouble".

2) Disconnect connector CN12.
1 Defective R clutch ECMV Resis-
Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN12 (male) (1), (2) – ground Min. 1 Mz
tance
Possible causes 2) Disconnect connectors ATC3 and CN12.
and standard Disconnection in wiring 3) Connect T-adapter.
value in normal harness
2 Wiring harness between ATC3 (female) (25) Resis-
state (Disconnection or defective Max. 1 z
– CN12 (female) (1) tance
contact)
Wiring harness between ATC3 (female) (23) Resis-
Max. 1 z
Defective sensing by speed
3 • Troubleshooting by the failure codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC3.
Defective transmission con- 3) Connect T-adapter.
4
troller
5 – 15 z
– ATC3 (female) (23) tance
8 HD465-7R, HD605-7R
HD465-7R, HD605-7R 9
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation

or setting) 1
Action code Failure code Reverse clutch disc abuse: Mistake in operation or setting
Trouble
— 15G7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
Failure code [15H0MW] (Hi clutch: Slipping) 1

Action code Failure code Hi clutch: Slipping
(Hi command is holding pressure, fill switch is ON, and slipping
Trouble
E03 15H0MW detected)
• When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the trans-
Contents of
mission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission
trouble
output shaft speed sensor is abnormal.
Action of • Shifts up and keeps gear according to gear speed before trouble and Table 1.
Problem that
appears on • If gearshift lever is set in neutral, machine cannot restart until it stops.
machine
• Can be checked with monitoring function (Code: 31600 (mA)).
• If electrical system is normal, check Hi clutch and mechanical/hydraulic system of pressure control
Related
valve for defect.
information

1 Defective Hi clutch ECMV Resis-
Between CN19 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
sensor
4
troller
5 – 15 z
12 HD465-7R, HD605-7R
Table 1
Remedy against trouble
Speed when trouble
Failed clutch Action of controller ON/OFF state of
was detected
(Selected clutch, gear speed) lockup clutch
4th 4th OFF NEUTRAL OFF
F7
High High OFF NEUTRAL OFF
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
Reverse Reverse OFF NEUTRAL OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 13
Failure code [15J0MW] (Lo clutch: Slipping) 1

Action code Failure code Lo clutch: Slipping
(Lo command is holding pressure, fill switch is ON, and slipping
Trouble
E03 15J0MW detected)
• When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the trans-
Contents of
mission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission
trouble
output shaft speed sensor is abnormal.
Action of • Shifts up and keeps gear according to gear speed before trouble and Table 1.
Problem that
appears on • If gearshift lever is set in neutral, machine cannot restart until it stops.
machine
• Can be checked with monitoring function (Code: 31601 (mA)).
• If electrical system is normal, check Lo clutch and mechanical/hydraulic system of pressure control
Related
valve for defect.
information

1 Defective Lo clutch ECMV Resis-
Between CN17 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
sensor
4
troller
5 – 15 z
14 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 15
Failure code [15K0MW] (1st clutch: Slipping) 1

Action code Failure code 1st clutch: Slipping
(1st command holding pressure, 1st clutch fill switch ON, slipping
Trouble
E03 15K0MW detected)
• During an output to the 1st clutch ECMV, an abnormality exists in the value calculated from the
Contents of
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
trouble
and transmission output shaft speed sensor.
• Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
Action of
Table 1.
controller
• Turns lock up to OFF.
1) Stop travel and set gearshift lever in N position.
Problem that 2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
appears on other to set machine in emergency escape mode.
machine 3) Operate gearshift lever and start machine again.
• Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA))
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st
clutch or pressure control valve.

1) Turn starting switch OFF.
2) Connect T-adapter to connector CN6 (male).
Resis-
1 Defective 1st clutch ECMV Between CN6 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and CN6
and standard Disconnection in wiring (female).
contact)
Max. 1 z
Defective speed sensor
3 • Troubleshooting by failure code DL**KA, DL**LC
detection
Defective transmission 2) Connect T-adapter to connector ATC3 (female).
4
controller Wiring harness between ATC3 (female) (36) Resis-
5 – 15 z
– (3) tance
16 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 17
Failure code [15L0MW] (2nd clutch: Slipping) 1

Action code Failure code 2nd clutch: Slipping
(2nd command holding pressure, 2nd clutch fill switch ON, slipping
Trouble
E03 15L0MW detected)
• During an output to the 2nd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
1 Defective 2nd clutch ECMV Between CN8 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN8 (male) (1), (2) and ground Min. 1 Mz
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
18 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 19
Failure code [15M0MW] (3rd clutch: Slipping) 1

Action code Failure code 3rd clutch: Slipping
(3rd command holding pressure, 3rd clutch fill switch ON, slipping
Trouble
E03 15M0MW detected)
• During an output to the 3rd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of • Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
controller Table 1.
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
1 Defective 3rd clutch ECMV Between CN10 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
20 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 21
Failure code [15N0MW] (4th clutch: Slipping) 1

Action code Failure code 4th clutch: Slipping
(4th command holding pressure, 4th clutch fill switch ON, slipping
Trouble
E03 15N0MW detected)
• During an output to the 4th clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 4th

Resis-
1 Defective 4th clutch ECMV Between CN14 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
22 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 23
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when

command current is OFF) 1
Action code Failure code R clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • Even when output to the R clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
trouble and the clutch is not released.
Action of
controller
Problem that
appears on • Machine cannot restart until it stops.
machine
Related • Fill switch input signal can be checked with code: 38919 (0: OFF, 1: ON).
information • If electrical system is normal, check hydraulic and mechanical systems of R clutch or pressure con-
trol valve for defect.

When R
Resis-
Defective for R clutch fill is disen- Min. 1 Mz
1 tance
switch Between CN13 (male) (1) – gaged
ground When R
Resis-
is Max. 1 z
tance
engaged
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect connectors ATC3 and CN13.
value in normal Defective harness grounding 3) Connect T-adapter to ATC3 (female).
2
state (Contact with ground circuit)
Min. 1 Mz
2) Connect T-adapter to connector ATC3 (female).
When R
Resis-
Defective transmission is disen- Min. 1 Mz
3 tance
controller Between ATC3 (female) (29) – gaged
ground When R
Resis-
is Max. 1 z
tance
engaged
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [15SBMA] (R clutch solenoid: Malfunction) 1

Action code Failure code R clutch solenoid: Malfunction
(R command holding pressure, R clutch fill switch OFF, slipping
Trouble
E03 15SBMA detected)
• The signal from the fill switch stays "OFF" during an output to the R clutch ECMV and an abnormal-
Contents of
ity exists in the value calculated from the signals of transmission input shaft speed sensor, transmis-
trouble
sion intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of • The controller sets the gear is neutral.
controller • Turns lock up to OFF.
Problem that
appears on • Machine cannot restart until it stops.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R

Resis-
1 Defective R clutch ECMV Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when

Action code Failure code Hi clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SCL1 (Transmission controller system)
Contents of • Even when output to the Hi clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
Table 2.
controller
Problem that
• Machine travels at gear speeds which use Hi clutch.
appears on
machine • Machine cannot travel in reverse.
information • If electrical system is normal, check hydraulic and mechanical systems of high clutch or pressure

When Hi
Resis-
is disen- Min. 1 Mz
1 Defective Hi clutch fill switch tance
Between CN20 (male) (1) – gaged
ground When Hi
Resis-
is Max. 1 z
tance
engaged
Possible causes
2) Disconnect connectors ATC3 and CN20.
and standard
2
state (Contact with ground circuit) Between ground and wiring harness
Resis-
between ATC3 (female) (30) – CN20 Min. 1 Mz
tance
(female) (1)
When Hi
Resis-
Defective transmission is disen- Min. 1 Mz
3 tance
controller Between ATC3 (female) (30) – gaged
ground When Hi
Resis-
is Max. 1 z
tance
engaged
28 HD465-7R, HD605-7R
Table 2
Speed when trouble Failed clutch
was detected (Fill switch ON) Action of controller ON/OFF state of
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
F7 1st OFF NEUTRAL OFF
High
Reverse OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRALR3 OFF
Reverse
R 2nd OFF NEUTRALR2 OFF
Low
1st OFF NEUTRAL OFF
High RH R OFF
N ANY NONE No reaction —
HD465-7R, HD605-7R 29
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 1

Action code Failure code Hi clutch solenoid: Malfunction
(Hi command holding pressure, Hi clutch fill switch OFF, slipping
Trouble
E03 15SCMA detected)
• The signal from the fill switch stays "OFF" during an output to the Hi clutch ECMV and an abnormal-
Contents of
ity exists in the value calculated from the signals of transmission input shaft speed sensor, transmis-
trouble
sion intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of
Table 1.
controller
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi

Resis-
1 Defective Hi clutch ECMV Between CN19 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
32 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 33
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when

Action code Failure code Lo clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SDL1 (Transmission controller system)
Contents of • Even when output to the Lo clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
• Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before fail-
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which use Lo clutch.
machine
information • If electrical system is normal, check hydraulic and mechanical systems of low clutch or pressure

When Lo
Resis-
is Min. 1 Mz
1 Defective Lo clutch fill switch tance
Between CN18 (male) (1) – released
ground When Lo
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
tance
(female) (1)
When Lo
Resis-
Defective transmission is Min. 1 Mz
3 tance
controller Between ATC3 (female) (10) – released
ground When Lo
Resis-
is Max. 1 z
tance
engaged
34 HD465-7R, HD605-7R
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 35
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 1

Action code Failure code Lo clutch solenoid: Malfunction
(Lo command holding pressure, Lo clutch fill switch OFF, slipping
Trouble
E03 15SDMA detected)
• The signal from the fill switch stays "OFF" during an output to the Lo clutch ECMV and an abnor-
Contents of
mality exists in the value calculated from the signals of transmission input shaft speed sensor, trans-
trouble
mission intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use Lo clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Lo

Resis-
1 Defective Lo clutch ECMV Between CN17 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
38 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 39
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when

Action code Failure code 1st clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • Even when output to the 1st clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 1st clutch.
appears on
machine • Machine cannot travels in reverse.
information • If electrical system is normal, check hydraulic and mechanical systems of 1st clutch or pressure

When 1st
Resis-
is Min. 1 Mz
1 Defective 1st clutch fill switch tance
Between CN7 (male) (1) – released
ground When 1st
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
between ATC3 (female) (40) – CN7 (female) Min. 1 Mz
tance
(1)
When 1st
Resis-
3 tance
ground When 1st
Resis-
is Max. 1 z
tance
engaged
40 HD465-7R, HD605-7R
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 41
42 HD465-7R, HD605-7R
HD465-7R, HD605-7R 43
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 1

Action code Failure code 1st clutch solenoid: Malfunction
(1st command holding pressure, 1st clutch fill switch OFF, slipping
Trouble
E03 15SEMA detected)
• The signal from the fill switch stays "OFF" during an output to the 1st clutch ECMV and an abnor-
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 1st clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st

Resis-
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
44 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 45

© 2007 KOMATSU
All Rights Reserved
46 HD465-7R, HD605-7R
SEN02534-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF) ..................... 3
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)............................................................................. 6
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF) ..................... 8
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ........................................................................... 12
Failure code [15SHL1] (4th clutch solenoid: Fill signal is ON when command current is OFF).................... 14
Failure code [15SHMA] (4th clutch solenoid: Malfunction) ........................................................................... 18
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction) ..................................................................... 20
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) ...................................................... 21
Failure code [2G42ZG] (Accumulator: Oil pressure reduction (Front)) ......................................................... 24
Failure code [2G43ZG] (Accumulator: Oil pressure reduction (Rear)).......................................................... 24
Failure code [989A00] (Engine over run prevention command signal: Operating) ....................................... 25
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated) ............................................... 25
Failure code [A570NX] (Engine oil filter: Clogging)....................................................................................... 26
Failure code [AA10NX] (Air cleaner element: Clogging)............................................................................... 28
Failure code [AB00MA] (Alternator: Malfunction).......................................................................................... 30
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)................... 32
HD465-7R, HD605-7R 1
Failure code [B@BAZK] (Engine oil: Level too low)...................................................................................... 34

Failure code [B@BCNS] (Engine: Overheat) ................................................................................................ 36
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level) ................................................... 38
Failure code [B@BFZK] (Lowering of fuel level) ........................................................................................... 40
Failure code [B@C7NS] (Brake cooling oil: Overheating (Rear)) ................................................................. 41
Failure code [B@CENS] (Overheating of torque converter oil)..................................................................... 42
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) .......................................................... 43
Failure code [B@JANS] (Steering oil temperature: Overheat)...................................................................... 44
2 HD465-7R, HD605-7R
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when

Action code Failure code 2nd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SFL1 (Transmission controller system)
Contents of • Even when output to the 2nd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 2nd clutch.
appears on
Related • Fill switch input signal can be checked with code: 38919 (0: OFF, 1:ON).
information • If electrical system is normal, check hydraulic and mechanical systems of 2nd clutch or pressure

When 2nd
Resis-
Defective fill switch for 2nd is Min. 1 Mz
1 tance
clutch Between CN9 (male) (1) – released
ground When 2nd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
between ATC3 (female) (9) – CN9 (female) Min. 1 Mz
tance
(1)
When 2nd
Resis-
3 tance
ground When 2nd
Resis-
is Max. 1 z
tance
engaged
HD465-7R, HD605-7R 3
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [15SFMA] (2nd clutch solenoid: Malfunction) 1

Action code Failure code 2nd clutch solenoid: Malfunction
(2nd command holding pressure, 2nd clutch fill switch OFF, slip-
Trouble
E03 15SFMA ping detected)
• The signal from the fill switch stays "OFF" during an output to the 2nd clutch ECMV and an abnor-
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 2nd clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
tance
Resis-
tance
contact)
Max. 1 z
detection
4
controller Wiring harness between ACT3 (female) (5) Resis-
5 – 15 z
– (23) tance
6 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 7
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when

Action code Failure code 3rd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SGL1 (Transmission controller system)
Contents of • Even when output to the 3rd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 3rd clutch.
appears on
information • If electrical system is normal, check hydraulic and mechanical systems of 3rd clutch or pressure

When 3rd
Resis-
Defective 3rd clutch fill is Min. 1 Mz
1 tance
switch Between CN11 (male) (1) – released
ground When 3rd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
tance
(female) (1)
When 3rd
Resis-
3 tance
ground When 3rd
Resis-
is Max. 1 z
tance
engaged
8 HD465-7R, HD605-7R
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
R 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 9
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) 1

Action code Failure code 3rd clutch solenoid: Malfunction
(3rd command holding pressure, 3rd clutch fill switch OFF, slipping
Trouble
E03 15SGMA detected)
• The signal from the fill switch stays "OFF" during an output to the 3rd clutch ECMV and an abnor-
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 3rd clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
12 HD465-7R, HD605-7R
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 13
Failure code [15SHL1] (4th clutch solenoid: Fill signal is ON when com-
mand current is OFF) 1
Action code Failure code 4th clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SHL1 (Transmission controller system)
Contents of • When output to 4th clutch ECMV is turned "OFF", signal from fill switch is kept "ON" and clutch is
trouble not disengaged.
Action of
ure.
controller
• Turns lockup system OFF.
Problem that
• Machine travels at gear speeds which use 4th clutch.
appears on
• Current output to ECMV can be checked with monitoring function (Code: 31605 (mA)).
information • If electrical system is normal, check hydraulic and mechanical systems of 4th clutch or pressure

1 Defective 4th clutch fill switch When dis- Resis-
Min. 1 Mz
Between CN15 (male) (1) – engaged tance
ground When Resis-
Max. 1 z
engaged tance
and standard Grounding fault in wiring 2) Disconnect connectors ATC3 and CN15.
value in normal 2 harness 3) Connect T-adapter to ATC3 (female).
state (Contact with ground circuit) Wiring harness between ATC3 (female) (20) Resis-
Min. 1 Mz
– CN15 (female) (1) and ground tance
3 When dis- Resis-
controller Min. 1 Mz
Between ATC3 (female) (20) – engaged tance
ground When Resis-
Max. 1 z
engaged tance
14 HD465-7R, HD605-7R
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
R1 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD465-7R, HD605-7R 15
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17
Failure code [15SHMA] (4th clutch solenoid: Malfunction) 1

Action code Failure code 4th clutch solenoid: Malfunction
(4th command is holding pressure, 4th clutch fill switch is OFF, and
Trouble
E03 15SHMA slipping detected)
• When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept "OFF" and the
Contents of
value calculated from the signals of the transmission input shaft speed sensor, transmission inter-
trouble
mediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.
Action of • The controller sets the gear in Neutral.
Problem that
• The gear is set in Neutral suddenly during travel.
appears on
machine • Machine travels at gear speeds which do not use 4th clutch.
Related
information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pres-
sure control valve for a defect.

1 Defective 4th clutch ECMV Resis-
Between CN14 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
Defective detection speed
sensor
4
troller
5 – 15 z
– (3) tance
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction) 1

Action code Failure code Lockup clutch solenoid: Malfunction
(Lockup command holding pressure is applied and slipping
Trouble
E03 15SJMA detected)
• During an output to the lockup clutch solenoid, an abnormality exists in the value calculated from
Contents of
the signals of engine speed sensor, transmission intermediated shaft speed sensor, and transmis-
trouble
sion output shaft speed sensor.
Action of • Holds gear speed during traveling and turns lock up to "OFF".
controller • Holds neutral when gear shift lever is set to "N".
Problem that
• Lockup is released and gear shift is disabled.
appears on
machine • If gear shift lever is shifted to "N", machine does not start unless it is stopped.
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for
lockup clutch or pressure control valve.

Defective lockup clutch Resis-
1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
20 HD465-7R, HD605-7R
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) 1

Action code Failure code Parking brake: Mistake in operation or setting
Trouble (Parking brake drags)
E03 2F00KM (Retarder controller system)
Contents of • When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency
trouble brake is operated.
Action of
controller
Problem that
appears on • If the machine is used without repairing, it may be broken.
machine
Related • If error in communication between transmission connector and retarder controller (DB1RKR) is dis-
information played, carry out troubleshooting for it first.

• Set the parking brake switch in the FREE position and then start
Mistake in operation of
1 the machine.
parking brake switch
• Do not use parking brake while machine is traveling.
2) Replace R03 with normal one.
When the parking Relay (R03) is
Yes
brake relay (R03) is defective
replaced, is failure Relay (R03) is
repaired? No
normal
2) Disconnect connector R03.
3) Check the relay.
Defective parking brake relay
2 Resis- 200 – 400
(R03) Between R03 (male) (1) – (2)
tance z
Possible causes 2) Disconnect connector R03.
and standard 3) Check the relay.
value in normal 4) Apply voltage between R03 (male) (1) – (2).
state
Apply 24 V between Resis-
Min. 1 Mz
Between R03 (male) (1) – (2) tance
(3) – (6) Do not apply 24 V Resis-
Max. 1 z
between (1) – (2) tance
2) Connect T-adapter to connector PSWR (male).
3) Start engine.
Set parking brake
Defective parking brake oil Resis-
3 switch in FREE Min. 1 Mz
pressure switch tance
Between PSWR position
(male) (1) – (2) Set parking brake
Resis-
switch in PARK Max. 1 z
tance
position
Mistake in operation of
emergency brake
4 • Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
HD465-7R, HD605-7R 21

2) Connect T-adapter to connector R03 (female).
Wiring harness between R03 (female) (2), Resis-
Max. 1 z
(6) – ground tance
Disconnection in wiring
harness
5 2) Connect T-adapter to connectors R03, BT3, and PSWR (female).
(Disconnection or defective
3) Check the relay.
contact)
Wiring harness between fuse BT3 (16) – Resis-
Max. 1 z
PSWR (female) (1) tance
Wiring harness between R03 (female) (1) – Resis-
Max. 1 z
and standard 2) Disconnect connectors BRC3 and R03.
value in normal Grounding fault of wiring 3) Connect T-adapter.
6
state harness
Wiring harness between BRC3 (female) (9), Resis-
Min. 1 Mz
R03 (female) (3) – ground tance
2) Disconnect connector BRC3.
4) Connect connector BRC3
7 Defective retarder controller Set parking brake
switch in FREE Voltage Max. 1 V
Between BRC3 (9) – position
ground Set parking brake
switch in PARK Voltage 20 – 30 V
position
22 HD465-7R, HD605-7R
HD465-7R, HD605-7R 23
Failure code [2G42ZG] (Accumulator: Oil pressure reduction (Front)) 1

Action code Failure code Accumulator: Oil pressure reduction (Front)
Trouble
E03 2G42ZG (Transmission controller system)
Contents of • Oil pressure reduction (Max. 13.2 (MPa) {135 (kg/cm2)}) was detected by signal from accumulator
trouble oil pressure sensor (front).
Action of
• Displays accumulator oil pressure monitor red.
controller
Problem that
appears on • Brake (Retarder) (front) does not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code: 35500 (MPa),
Related
35504 (V)).
information
• Circuit diagram: See [DHU2KX].

Possible causes Hydraulic system (pump, relief valve or piping) may have trouble.
1 Trouble in hydraulic system
and standard If pressure is reduced, remove cause of trouble.
value in normal If cause 1 is not detected, accumulator (front) oil pressure sensor
state Defective accumulator (front)
2 system may be defective. Carry out troubleshooting for failure
oil pressure sensor system
code [DHU2KX].
Failure code [2G43ZG] (Accumulator: Oil pressure reduction (Rear)) 1

Action code Failure code Accumulator oil pressure reduction (Rear)
Trouble
E03 2G43ZG (Transmission controller system)
Contents of • Oil pressure reduction (Max. 8.83 (MPa) {90 (kg/cm2)}) was detected by signal from accumulator oil
trouble pressure sensor (rear).
Action of
• Displays accumulator oil pressure monitor red.
controller
Problem that
appears on • Brake (Retarder) (rear) does not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code: 35501 (MPa),
Related
35505 (V)).
information
• Circuit diagram: See [DHU3KX].

Possible causes Hydraulic system (pump, relief valve or piping) may have trouble.
1 Trouble in hydraulic system
and standard If pressure is reduced, remove cause of trouble.
value in normal If cause 1 is not detected, accumulator (rear) oil pressure sensor
state Defective accumulator (rear)
2 system may be defective. Carry out troubleshooting for failure
oil pressure sensor system
code [DHU3KX].
24 HD465-7R, HD605-7R
Failure code [989A00] (Engine over run prevention command signal:

Operating) 1
Action code Failure code Engine over run prevention command signal: Operating
Trouble
E02 989A00 (Machine monitor system)
Contents of • When gear speed is set at the position other than neutral, transmission input shaft speed signal
trouble exceeds the input shaft speed which is set for each gear speed to prevent over run.
Action of
• Send out command signal to retarder controller and activate brake.
machine monitor
Problem that
appears on • Brake becomes activated and travel speed lowers.
machine
• Input shaft speed can be checked in monitoring function (code: 31200 (rpm)).
Related
information • Information on operation of engine overrun prevention command is obtained from transmission con-
troller through network.

a If machine is so traveling that transmission input shaft speed sig-
Possible causes
1 Engine over run nal exceeds 2,600 rpm (or 2,400 rpm at R2), engine is overrun-
and standard
ning.
value in normal
state • If machine is not so traveling that transmission input shaft speed
2 signal exceeds 2,600 rpm (or 2,400 rpm at R2), transmission
controller
controller is defective.
Failure code [989D00] (Rear section tipping over alarm: Alarm is

activated) 1
Action code Failure code Rear section tipping over alarm: Alarm is activated
Trouble (Lift operation when machine is inclined)
— 989D00 (Machine monitor system)
Contents of
• Body is lifted when machine is inclined.
trouble
Action of
• Turns on inclination caution lamp
machine
monitor • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If body is lifted in such condition, machine body may tip over.
machine
• Input signal from pitch angle sensor can be checked with monitoring function (code: 32900 (°),
Related 32903 (V)).
information • Information on operation of inclination alarm activation is obtained from transmission controller
through network.

and standard
value in normal 1 Mistake in operation Do not lift body when machine is inclined for more than 15°.
state
HD465-7R, HD605-7R 25
Failure code [A570NX] (Engine oil filter: Clogging) 1

Action code Failure code Engine oil filter: Clogging
Trouble
E01 A570NX (Retarder controller system)
• When engine speed is above 500 rpm and torque converter oil temperature is above 50°C, and
Contents of
engine coolant temperature is above 67°C, oil filter circuit is opened (disconnected from ground cir-
trouble
cuit).
Action of
controller
Problem that
appears on • If engine is used for long hours, it may be seized.
machine
Related
information

When maintenance caution lamp
1 Clogged oil filter Oil filter is probably clogged
is lighting
2) Disconnect switch terminal E05.
Resis-
Defective oil filter clogging Terminal of switch Oil filter
2 tance
switch
When normal Max. 1 z
Between E05 – ground When clogging
Min. 1 Mz
Possible causes switch is open
and standard 1) Turn starting switch OFF.
value in normal Disconnection in wiring 2) Disconnect connector BRC2 and switch terminal E05.
state harness 3) Connect T-adapter to BRC2 (female).
3
(Disconnection in wiring or
defective contact in connector) Wiring harness between BRC2 (female) Resis-
Max. 1 z
(13) – terminal E05 tance
2) Insert T-adapter in connector BRC2.
3) Turn starting switch ON.
4 Defective retarder controller BRC2 Oil filter Voltage
When normal Max. 1 V
Between (13) – ground When clogging
20 – 30 V
switch is open
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
Failure code [AA10NX] (Air cleaner element: Clogging) 1

Action code Failure code Air cleaner element: Clogging
Trouble
E01 AA10NX (Transmission controller system)
Contents of
• The air cleaner clogging signal circuit is "opened" (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If the machine is used without repairing, the suction performance of the engine may be lowered.
machine
Related
• ATC2 (17) When normal: GND, When clogged: OPEN
information

The dust indicator is not red Air cleaner is normal
1 Clogging of air cleaner
The dust indicator is red Air cleaner is clogged
2) Replace R32 with normal one.
3) Turn the starting switch ON.
When the dust indicator relay No Relay is normal

(R32) is replaced, is failure
repaired? Yes Relay is defective

Dust indicator relay (R32) 3) Check the relay.
2
defective Resis- 200 – 400
Between R32 (male) (1) – (2)
tance z
Possible causes 3) Check the relay.
and standard 4) Apply voltage between R32 (male) (1) – (2).
value in normal Apply 24 V between Resis-
state Min. 1 Mz
Between R32 (male) (1) – (2) tance
(3) – (6) Do not apply 24 V Resis-
Max. 1 z
between (1) – (2) tance
2) Disconnect connector FR01.
Defective air cleaner clog- 4) Turn the starting switch ON.
3 a Inside of air cleaner sensor is consist of electric circuit,so it is
ging sensor
impossible to judge with resistance.
Between FR01 Air cleaner is normal Voltage 20 – 30 V
(male) (1) – (2) Air cleaner is clogged Voltage Max. 10 V
2) Disconnect connectors ATC2, ATC3 and R32.
harness
– R32 (female) (6) tance
contact)
Max. 1 z
– R32 (female) (3) tance
28 HD465-7R, HD605-7R

2) Disconnect connectors R32 and FR01.
Grounding fault of wiring har- 3) Connect T-adapter.
5
Possible causes ness
and standard Min. 1 Mz
FR01 (female) (1) – ground tance
value in normal
state 1) Turn starting switch OFF.
2) Insert T-adapter in connectors ATC3 and ATC2.
Defective transmission con- 3) Turn starting switch ON.
6
troller
Between ATC2 (17) – Air cleaner is normal Voltage Max. 1 V
ATC3 (21) Air cleaner is clogged Voltage 20 – 30 V
HD465-7R, HD605-7R 29
Failure code [AB00MA] (Alternator: Malfunction) 1

Action code Failure code Alternator: Malfunction
Trouble (Failure in battery charging circuit)
E03 AB00MA (Transmission controller system)
Contents of
• A generation signal is not input from the alternator while the engine is running.
trouble
Action of
controller
Problem that
• If the machine is used without repairing, the source voltage may lower so much that the machine
appears on
cannot travel.
machine
Related
• This failure can be checked in the monitoring function (Code: 04301 (0: OFF, 1:ON)).
information

2) Disconnect connector alternator terminal R.
1 Defective alternator 27.5 –
Between alternator R – E Voltage
29.5 V
a If the battery is deteriorated or used in a cold district, the volt-
age may not rise for a while after the engine is started.
Possible causes 27.5 –
and standard Disconnection in wiring Between ATC1 (female) (5) – ground Voltage
harness 29.5 V
value in normal 2
state (Disconnection or defective a If the battery is deteriorated or used in a cold district, the volt-
contact) age may not rise for a while after the engine is started.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M – alternator terminal R tance
Defective transmission con- 4) Start the engine.
3
troller
Between ATC1 (5) – ground Voltage 20 – 30 V
a If the battery is deteriorated or used in a cold district, the volt-
age may not rise for a while after the engine is started.
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure:

Lowering of oil pressure) 1
Action code Failure code Abnormal lowering of engine oil pressure: Lowering of oil pressure
Trouble
E03 B@BAZG (Engine controller system)
Contents of • When engine speed was below 500 rpm for 15 seconds, engine oil pressure became lower than
trouble operating range.
Action of • Limit output for travel (Limit injection rate and engine speed)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitor-
ing function (Code: 37200 (kPa)).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 (V)).
• Method of reproducing failure code: Start engine.

Defective sensor power sup- If failure code [CA187] or [CA227] is also indicated, carry out trou-
1
ply system bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sen-
2 Between (1) and (2) Power supply 4.75 – 5.25V
sor (Internal defect)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
Max. 1 z
ness – POIL (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (47) Resis-
Possible causes contact of connector) Max. 1 z
– POIL (female) (2) tance
and standard
value in normal Wiring harness between ENG (female) (13) Resis-
Max. 1 z
state – POIL (female) (3) tance
Wiring harness between ENG (female) (37) Resis-
Grounding fault in wiring har- – POIL (female) (1) Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
Min. 1 Mz
ENG Voltage
5 Defective engine controller Between
Power supply 4.75 – 5.25V
(37) and (47)
Between
Signal 0.3 – 4.7 V
(13) and (47)
32 HD465-7R, HD605-7R
HD465-7R, HD605-7R 33
Failure code [B@BAZK] (Engine oil: Level too low) 1

Action code Failure code Engine oil: Level too low
Trouble
E01 B@BAZK (Retarder controller system)
Contents of
• Engine oil level switch circuit has become "OPEN" (disconnected with GND).
trouble
Action of
• Turn on the maintenance caution lamp.
controller
Problem that
appears on • If machine is operated in such a condition, engine may be seized.
machine
Related • This trouble is not detected while engine coolant temperature is above 60°C.
information • This failure code is reset when engine is started.

• Engine oil level is normal.
1 Engine oil level is too low. a If engine oil level is too low, check for an oil leakage around
engine before refilling.
a Prepare with starting switch OFF and troubleshooting with
starting switch still OFF.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between E04 (male) normal tance
Possible causes (1) and ground Engine oil level is too Resis-
Min. 1 Mz
and standard low tance
value in normal
Disconnection in wiring a Prepare with starting switch OFF and troubleshooting with
state
harness starting switch still OFF.
3
(Disconnection or defective Wiring harness between BRC2 (female) (7) Resis-
contact) Max. 1 z
– E04 (female) (1) tance
starting switch ON.
Defective retarder Engine oil level is
4 Voltage Max. 1V
controller Between BRC2 (7) – normal
ground Engine oil level is too
Voltage 20 – 30 V
low
34 HD465-7R, HD605-7R
HD465-7R, HD605-7R 35
Failure code [B@BCNS] (Engine: Overheat) 1

Action code Failure code Engine overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of • When engine speed was below 500 rpm for 3 seconds or more, coolant temperature exceeded
trouble operating range.
Action of • Limits output and continues operation.
Problem that
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the moni-
toring function (Code: 04104 (°C)).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information

Defective coolant tempera- without turning starting switch ON.
1
ture sensor (Internal defect) TWTR (male) Coolant temperature Resistance
Between (A) and (B) 10 – 100°C 0.6 – 20 kz
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between ENG (female) (15) Resis-
value in normal 2 Max. 1 z
(Disconnection or defective – TWTR (female) (A) tance
state contact of connector) Wiring harness between ENG (female) (38) Resis-
Max. 1 z
– TWTR (female) (B) tance
3 Defective engine controller ENG (female) Coolant temperature Resistance
Between
10 – 100°C 0.6 – 20 kz
(15) and (38)
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of

level) 1
Action code Failure code Lowering of radiator coolant: Lowering of level
Trouble
E01 B@BCZK (Transmission controller system)
Contents of
• The radiator coolant level switch signal circuit is opened (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If machine is used while coolant level is low, engine may overheat.
machine
Related
information

• The radiator coolant level is normal.
Lowering of radiator coolant
1 a If the radiator coolant level is low, check around the engine
level
and radiator for coolant leakage before adding coolant.
2) Disconnect connector FL02.
Defective radiator coolant
2 Radiator coolant Resis-
level switch Max. 1 z
Between FL02 (male) level is normal tance
(1) – (2) Radiator coolant Resis-
Min. 1 Mz
level is low tance
and standard 2) Disconnect connectors ATC2, ATC3 and FL02.
value in normal Disconnection in wiring 3) Connect T-adapter.
state harness
– FL02 (female) (1) tance
contact)
Wiring harness between FL02 (female) (2) – Resis-
Max. 1 z
ATC3 (female) (21) tance
Defective transmission con- 4) Turn the starting switch ON.
4
troller Radiator coolant
Between ATC2 Voltage Max. 1V
level is normal
(female) (27) – ATC3
(female) (21) Radiator coolant
Voltage 20 – 30 V
level is low
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39
Failure code [B@BFZK] (Lowering of fuel level) 1

Action code Failure code Lowering of fuel level
Trouble
– B@BFZK (Machine monitor system)
Contents of
• Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 z or higher is detected).
trouble
Action of • Does not display this failure code, if DJF1KA is detected.
machine monitor • Turns fuel level caution lamp ON.
Problem that
appears on • None in particular.
machine
• When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient.
Related • Signal from fuel level sensor can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200 (V) / 04201 (z z))
• Method of reproducing failure code: Turn starting switch ON.

Possible causes
Lack of fuel (When system is
and standard 1 Fuel may be insufficient. Check and add fuel, if necessary.
normal)
value in normal
state Carry out troubleshooting for failure code [DJF1KA], if fuel is suffi-
2 Defective fuel level sensor
cient.
40 HD465-7R, HD605-7R
Failure code [B@C7NS] (Brake cooling oil: Overheating (Rear)) 1

Action code Failure code Brake cooling oil: Overheating (Rear)
Trouble
E02 B@C7NS (Machine monitor system)
Contents of • While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temper-
trouble ature sensor.
Action of
• Turn on brake oil temperature caution lamp.
machine monitor
Problem that
• Brake (Retarder) (Rear) comes not to work.
appears on
machine • If machine is used as it is, brake (retarder) (rear) may be damaged.
• Input signal from oil temperature sensor can be checked with monitoring function (Code: 30211
Related (°C), 30212 (V)).
information • For troubleshooting for brake (retarder) (rear) oil temperature sensor, see failure code [DGR2KZ].
• If R14 (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.

Overheating of rear brake
1 Rear brake may be overloaded. Check it directly.
cooling oil
Possible causes Defective brake oil
2 Carry out troubleshooting for [DGR2KB] and [DGR2KZ].
and standard temperature sensor
value in normal 3 Defective BCV-related circuit Carry out troubleshooting for [DW78KZ].
state
If causes 1 – 3 are not detected, retarder controller may be defec-
4 Defective retarder controller
tive.
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor
tive.
HD465-7R, HD605-7R 41
Failure code [B@CENS] (Overheating of torque converter oil) 1

Action code Failure code Overheating of torque converter oil
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• Torque converter oil is overheating.
trouble
Action of
• Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If machine is used as it is, torque converter may be broken.
machine
• Signal of torque converter oil temperature sensor is input to transmission controller and then its
Related information is transmitted to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.
(Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100 (°C) / 30101(V))

Overheating of torque con-
Possible causes Torque converter oil may be overheating. Check for cause and
1 verter oil (When system is
and standard repair.
normal)
value in normal
state Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KX].
42 HD465-7R, HD605-7R
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) 1

Action code Failure code Battery electrolyte level: Lowering of level
Trouble
E01 B@GAZK (Retarder controller system)
Contents of
• While engine speed is below 100 rpm, input signal is closed (disconnected from ground circuit).
trouble
Action of
controller
Problem that
appears on • If machine is used as it is, battery is deteriorated.
machine
Related
information

Check battery electrolyte level. If it is low, add new electrolyte.
1 Low battery electrolyte level
(If this trouble occurs frequently, check for overcharging.)
2) Connect T-adapter to connector BTL (male).
Defective battery electrolyte Battery electrolyte Resis-
2 BTL (male)
level switch level tance
Possible causes When normal Max. 1 z
Between (1) – ground
and standard When low Min. 1 Mz
value in normal
state Disconnection in wiring 2) Connect T-adapter to connectors BRC2(female) (38) and BTL
harness (female).
3
(Disconnection in wiring or
defective contact in connector) Wiring harness between BRC2 (female) Resis-
Max. 1 z
(38) – BTL (female) (1) tance
2) Connect T-adapter to connector BRC2 (female).
4 Defective retarder controller 3) Turn starting switch ON.
Between BRC2 (female) (38) – ground Voltage 20 – 30 V
HD465-7R, HD605-7R 43
Failure code [B@JANS] (Steering oil temperature: Overheat) 1

Action code Failure code Steering oil temperature: Overheat
Trouble
E02 B@JANS (Transmission controller system)
Contents of • Voltage of steering temperature sensor circuit has become below 1.61 V (oil temperature is above
trouble 120°C).
Action of
• Turn on steering oil temperature caution lamp.
controller
• Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If machine is operated in such a condition, it may cause an oil leakage.
machine
Related
• Steering oil temperature can be checked with monitoring function (code: 32701 (°C) and 32702 (V)).
information

Steering oil temperature is
Possible causes overheated. Since the overheat of the steering oil can be suspected, if there is
1
and standard (When the system is operat- an overheat, repair the cause of the failure.
value in normal ing normally)
state If cause 1 is not detected, steering oil temperature sensor system
Defective steering oil
2 may be defective. Carry out troubleshooting for failure code
temperature sensor
[DGR6KX].
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45

© 2007 KOMATSU
All Rights Reserved
46 HD465-7R, HD605-7R
SEN02535-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [CA111] (Abnormality in engine controller) ................................................................................. 4
Failure code [CA115] (Engine Ne or Bkup speed sensor error)...................................................................... 6
Failure code [CA122] (Charge pressure sensor high error)............................................................................ 8
Failure code [CA123] (Charge pressure sensor low error) ........................................................................... 10
Failure code [CA131] (Throttle sensor high error) ........................................................................................ 12
Failure code [CA132] (Throttle sensor low error).......................................................................................... 14
Failure code [CA135] (Engine oil pressure sensor high error)...................................................................... 16
Failure code [CA141] (Engine oil pressure sensor low error) ....................................................................... 18
Failure code [CA144] (Coolant temperature sensor high error) .................................................................... 20
Failure code [CA145] (Coolant temperature sensor low error) ..................................................................... 22
Failure code [CA153] (Charge temperature sensor high error) .................................................................... 24
Failure code [CA154] (Charge temperature sensor low error)...................................................................... 26
Failure code [CA187] (Sensor power supply 2 low error) ............................................................................. 26
Failure code [CA212] (Engine oil temperature sensor high error) ................................................................ 28
Failure code [CA213] (Engine oil temperature sensor low error).................................................................. 30
Failure code [CA221] (Atmospheric pressure sensor high error).................................................................. 32
HD465-7R, HD605-7R 1
Failure code [CA222] (Atmospheric pressure sensor low error) ................................................................... 34

Failure code [CA227] (Sensor power supply 2 high error) ............................................................................ 36
Failure code [CA234] (Engine overspeed) .................................................................................................... 38
Failure code [CA238] (Ne speed sensor power supply error) ....................................................................... 40
Failure code [CA263] (Fuel temperature sensor high error) ......................................................................... 42
Failure code [CA265] (Fuel temperature sensor low error)........................................................................... 44
Failure code [CA271] (PCV1 Short circuit).................................................................................................... 46
Failure code [CA272] (PCV1 Disconnection) ................................................................................................ 48
Failure code [CA273] (PCV2 Short circuit).................................................................................................... 50
Failure code [CA274] (PCV2 Disconnection) ................................................................................................ 52
Failure code [CA322] (Injector #1 open/short error)...................................................................................... 54
Failure code [CA342] (Calibration code inconsistency) ................................................................................ 66
Failure code [CA351] (Injectors drive circuit error)........................................................................................ 66
Failure code [CA352] (Sensor power supply 1 low error) ............................................................................. 67
Failure code [CA386] (Sensor power supply 1 high error) ............................................................................ 68
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Failure code [CA111] (Abnormality in engine controller) 1
Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
• Internal defect occurred in controller.
trouble
Action of
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related • Method of reproducing failure code: Turn the starting switch ON.
information • Source voltage of engine controller can be checked with monitoring function (Code: 03200 (V)).

Defective circuit breaker Circuit breaker (FuA1) may be defective. Check it directly.
1
(FuA1) (If circuit breaker is turned OFF, circuit probably has ground fault.)
1) Disconnect battery ground cable.
2) Remove 5th BT3 from bottom.
2 Broken fuse
There is
Between fuse terminals Continuity
continuity
a Turn starting switch OFF and disconnect battery ground cable,
Disconnection in wiring then carry out troubleshooting.
harness
Wiring harness between J3P (female) (4) – Resis-
Possible causes 3 (Disconnection in wiring Max. 1 z
battery (+) tance
and standard or defective contact in
value in normal connector) Wiring harness between J3P (female) (1) – Resis-
Max. 1 z
state ground tance
a Turn starting switch OFF and disconnect battery ground cable,
Grounding fault in wiring then carry out troubleshooting.
4 harness
(Contact with ground circuit) Wiring harness between J3P (female) (4) – Resis-
Min. 1 Mz
battery (+) and ground tance
3) Connect T-adapter to J3P.
5 Defective engine controller 4) Connect battery ground cable and carry out troubleshooting.
J3P Voltage
Between (3), (4) – (1), (2) 20 – 30 V
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 1
Action code Failure code Engine Ne or Bkup speed sensor error

Trouble
Contents of
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
trouble
Action of
• Stop the engine.
controller
Problem that
• The engine does not start. (if engine has been stopped.)
appears on
• Engine stops. (if engine has been running.)
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Ne speed sensor may be installed defectively. Check it directly.
Defective installation of Ne
Possible causes 3 (Defective installation of sensor itself, internal defect of flywheel,
speed sensor
and standard etc.)
value in normal Bkup speed sensor may be installed defectively. Check it directly.
state Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply
speed sensor
pump, etc.)
Defective sensor connection Ne and Bkup speed sensors may be connected defectively
5
(Improper connection) (improper connection). Check them directly.
If causes 1 – 5 are not the cause of the trouble, the engine control-
6 Defective engine controller ler may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
6 HD465-7R, HD605-7R
HD465-7R, HD605-7R 7
Failure code [CA122] (Charge pressure sensor high error) 1
Action code Failure code Charge pressure sensor high error

Trouble
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally high.
trouble
Action of • Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
controller tion.
Problem that
• Engine does not accelerate smoothly.
appears on
• More black smoke is produced during acceleration.
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related
• Charge pressure (boost pressure) sensor input signal can be checked with code: code 36500 (kPa) /
information
code 36502 (V).

Defective power supply sys-
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 tem of charge pressure sen-
bleshooting for it first.
sor (boost pressure sensor)
Defective charge pressure PIM Voltage
sensor
(boost pressure sensor)
(Internal defect) Charge pressure sensor voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring harness
and controller for another cause of trouble before judgment.
Possible causes
and standard
value in normal
state Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
Max. 1 z
ness – PIM (female) (1) tance
3
contact of connector) Max. 1 z
– PIM (female) (3) tance
Max. 1 z
– PIM (female) (2) tance
Grounding fault in wiring har-
4 ness Min. 1 Mz
– PIM (female) (1) and ground tance
(Contact with ground circuit)
Min. 1 Mz
– PIM (female) (2) and ground tance
8 HD465-7R, HD605-7R

Wiring harness between ENG (female) (37)
Resis-
– PIM (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring (female) (47) – PIM (female) (3)
5 harness Wiring harness between ENG (female) (37)
(with another wiring harness) – PIM (female) (1) and between ENG Resis-
Min. 1 Mz
tance
Possible causes (female) (44) – PIM (female) (2)
and standard Wiring harness between ENG (female) (47)
Resis-
value in normal – PIM (female) (2) and between ENG Min. 1 Mz
tance
state (female) (44) – PIM (female) (2)
2) Connect T-adapter to connector ENG.
ENG Voltage
6 Defective engine controller
Between
(37) and (47)
Between
Signal 0.3 – 4.7 V
(44) and (47)
HD465-7R, HD605-7R 9
Failure code [CA123] (Charge pressure sensor low error) 1
Action code Failure code Charge pressure sensor low error

Trouble
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally low.
trouble
Action of • Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
controller tion.
Problem that
• Engine does not accelerate smoothly.
appears on
• More black smoke is produced during acceleration.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 (kPa)).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502 (V)).

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
Failure code [CA131] (Throttle sensor high error) 1
Action code Failure code Throttle sensor high error

Trouble
Contents of
• Throttle sensor circuit is abnormally high (Min. 4.5 V)
trouble
Action of
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 36% when it is ON.
controller
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701 (%)).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function
information
(Code: 31707 (V)).

Defective throttle sensor If failure code [CA2185] or [CA2186] is also indicated, carry out
1
power supply system troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
AS1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25V
(Power supply)
Defective accelerator pedal (17 ± 2% of power
2 When released
(Internal defect) supply)*
Between (2) and (3)
(82 ± 2% of power
When pressed
supply)*
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
Possible causes too, for another cause of trouble, and then judge.
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring har- Wiring harness between J2P (female) (22) – Resis-
Max. 1 z
ness AS1 (female) (1) tance
3
(Disconnection or defective Wiring harness between J2P (female) (9) – Resis-
AS1 (female) (2) tance
Max. 1 z
Grounding fault in wiring har- AS1 (female) (1) and ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between J2P (female) (9) – Resis-
Min. 1 Mz
AS1 (female) (2) and ground tance
Min. 1 Mz
12 HD465-7R, HD605-7R

Possible causes J2P Accelerator pedal Voltage
and standard Between All range
value in normal 4.75 – 5.25V
5 Defective engine controller (22) and (23) (Power supply)
state
(17 ± 2% of power
When released
supply)*
Between (9) and (23)
(82 ± 2% of power
When pressed
supply)*
* Refer to Fig. 1
Fig. 1 Pedal: Stroke of accelerator pedal

Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1
and switch 2
HD465-7R, HD605-7R 13
Failure code [CA132] (Throttle sensor low error) 1
Action code Failure code Throttle sensor low error

Trouble
Contents of
• Throttle sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
Related
itoring function (Code: 31701 (%), 31707 (V)).
information

and standard
state
14 HD465-7R, HD605-7R
HD465-7R, HD605-7R 15
Failure code [CA135] (Engine oil pressure sensor high error) 1
Action code Failure code Engine oil pressure sensor high error
Trouble
Contents of
• Engine oil pressure sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 (kPa)).
Related
information

1 tem of engine oil pressure
sensor
1) Prepare with starting switch OFF, then turn starting switch ON or
2) Insert T-adapter (Connector: ENG)
Defective engine oil pressure POIL Voltage
2
sensor (Internal defect)
Between (1) and (2) Power supply 4.75 – 5.25V
and standard
value in normal
state
Max. 1 z
ness – POIL (female) (1) tance
3
Max. 1 z
4 ness Min. 1 Mz
– POIL (female) (1) and ground tance
Min. 1 Mz
– POIL (female) (3) and ground tance
16 HD465-7R, HD605-7R

Resis-
– POIL (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
5 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – POIL (female) (1) and between ENG Resis-
Min. 1 Mz
tance
Possible causes (female) (13) – POIL (female) (3)
and standard Wiring harness between ENG (female) (47)
Resis-
value in normal – POIL (female) (2) and between ENG Min. 1 Mz
tance
state (female) (13) – POIL (female) (3)
2) Insert T-adapter (Connector: POIL)
ENG Voltage
Between
(37) and (47)
Between
Signal 0.3 – 4.7 V
(13) and (47)
HD465-7R, HD605-7R 17
Failure code [CA141] (Engine oil pressure sensor low error) 1
Action code Failure code Engine oil pressure sensor low error
Trouble
Contents of
• Engine oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 (kPa)).
Related
information

and standard
state
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [CA144] (Coolant temperature sensor high error) 1
Action code Failure code Coolant temperature sensor high error

Trouble
Contents of
• Coolant sensor circuit is abnormally high.
trouble
Action of
• Sets coolant temperature to fixed value (90°C), and continues operation.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitor-
ing function (Code: 04104 (°C)).
Related
information

Defective coolant tempera- without turning starting switch ON.
1
ture sensor (Internal defect) TWTR (male) Coolant temperature Resistance
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (15) Resis-
2 Max. 1 z
Possible causes (Disconnection or defective – TWTR (female) (A) tance
and standard contact of connector) Wiring harness between ENG (female) (38) Resis-
value in normal Max. 1 z
– TWTR (female) (B) tance
state
Grounding fault in wiring har- without turning starting switch ON.
3 ness
Min. 1 Mz
– TWTR (female) (A) and ground tance
4 Defective engine controller ENG (female) Coolant temperature Resistance
Between
10 – 100°C 0.6 – 20 kz
(15) and (38)
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [CA145] (Coolant temperature sensor low error) 1
Action code Failure code Coolant temperature sensor low error

Trouble
Contents of
• Coolant sensor circuit is abnormally low.
trouble
Action of
• Sets coolant temperature to fixed value (90°C), and continues operation.
controller
Problem that
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitor-
ing function (Code: 04104 (°C)).
Related
information

and standard
state
22 HD465-7R, HD605-7R
HD465-7R, HD605-7R 23
Failure code [CA153] (Charge temperature sensor high error) 1
Action code Failure code Charge temperature sensor high error

Trouble
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally high.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C), and continues operation.
controller
Problem that
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500 (°C)).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501 (V)).

Defective charge tempera-
ture sensor TIM (male) Air boost temperature Resistance
1
(boost temperature sensor) Between (A) and (B) 10 – 100°C 0.5 – 20 kz
(Internal defect)
Between (A) and
In all range Min. 1 Mz
ground
Possible causes ness Wiring harness between ENG (female) (23) Resis-
2 Max. 1 z
and standard (Disconnection or defective – TIM (female) (A) tance
value in normal contact of connector) Wiring harness between ENG (female) (47) Resis-
state Max. 1 z
– TIM (female) (B) tance
3 ness
Min. 1 Mz
– TIM (female) (A) and ground tance
4 Defective engine controller ENG (female) Air boost temperature Resistance
Between
10 – 100°C 0.5 – 20 kz
(23) and (47)
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [CA154] (Charge temperature sensor low error) 1
Action code Failure code Charge temperature sensor low error

Trouble
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally low.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C), and continues operation.
controller
Problem that
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500 (°C)).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501 (V)).

and standard
state
Failure code [CA187] (Sensor power supply 2 low error) 1
Action code Failure code Sensor power supply 2 low error

Trouble
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Bkup speed sensor: Operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and
Action of
continues operation.
controller
• Charge pressure sensor sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}), and continues
operation.
• Limits output and closes EGR valve and bypass valve. (Ignores signals from EGR valve lift sensor
and bypass valve lift sensor.)
Problem that
machine
Related
information

and standard
state
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
Failure code [CA212] (Engine oil temperature sensor high error) 1
Action code Failure code Engine oil temperature sensor high error
Trouble
Contents of
• Engine oil temperature sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil temperature to fixed value (100°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (temperature) from the engine oil temperature sensor can be checked with the moni-
toring function (Code: 42700 (°C)).
Related
• The input state (voltage) from the engine oil temperature sensor can be checked with the monitoring
information

Defective engine oil temper- without turning starting switch ON.
1
ature sensor (Internal defect) TOIL (male) Oil temperature Resistance
2 Max. 1 z
Possible causes (Disconnection or defective – TOIL (female) (A) tance
– TOIL (female) (B) tance
state
3 ness
Min. 1 Mz
– TOIL (female) (A) and ground tance
4 Defective engine controller ENG (female) Oil temperature Resistance
Between
10 – 100°C 0.6 – 20 kz
(17) and (47)
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [CA213] (Engine oil temperature sensor low error) 1
Action code Failure code Engine oil temperature sensor low error
Trouble
Contents of
• Engine oil temperature sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil temperature to fixed value (100°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil temperature) from the engine oil temperature sensor can be checked with the
monitoring function (Code: 42700 (°C)).
Related
• The input state (voltage) from the engine oil temperature sensor can be checked with the monitoring
information

and standard
state
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31
Failure code [CA221] (Atmospheric pressure sensor high error) 1
Action code Failure code Atmospheric pressure sensor high error

Trouble
Contents of
• Atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 (kPa)).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information

1 tem of atmospheric pressure
sensor
2) Connect T-adapter to connector PAMB.
PAMB Voltage
Defective atmospheric pres-
sure sensor (Internal defect)
Between (2) and (3) Signal 0.3 – 4.7 V
and standard
Max. 1 z
ness – PAMB (female) (1) tance
3
– PAMB (female) (3) tance
Wiring harness between ENG (female) (3) – Resis-
Max. 1 z
PAMB (female) (2) tance
4 ness Min. 1 Mz
– PAMB (female) (1) and ground tance
Min. 1 Mz
PAMB (female) (2) and ground tance
32 HD465-7R, HD605-7R

Resis-
– PAMB (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – PAMB (female) (3)
(with another wiring harness) – PAMB (female) (1) and between ENG Resis-
Possible causes Min. 1 Mz
tance
and standard (female) (3) – PAMB (female) (2)
value in normal Wiring harness between ENG (female) (38)
Resis-
state – PAMB (female) (3) and between ENG Min. 1 Mz
tance
(female) (3) – PAMB (female) (2)
6 Defective engine controller ENG Voltage
Between (37) and (38) 4.75 – 5.25V
Between (3) and (38) 0.3 – 4.7 V
HD465-7R, HD605-7R 33
Failure code [CA222] (Atmospheric pressure sensor low error) 1
Action code Failure code Atmospheric pressure sensor low error

Trouble
Contents of
• Atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 (kPa)).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information

and standard
state
34 HD465-7R, HD605-7R
HD465-7R, HD605-7R 35
Failure code [CA227] (Sensor power supply 2 high error) 1
Action code Failure code Sensor power supply 2 high error

Trouble
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
Action of
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and
controller
continues operation.
• Charge pressure sensor (boost pressure sensor) sets charge pressure to fixed value (400 kPa {4.1
kg/cm2}), and continues operation.
Problem that
machine
Related
information

1 Related system defects If another code is displayed, carry out troubleshooting for it first.
Bkup speed sensor
G connector
Disconnect device system
Defective sensor suggested on the
2 Oil pressure sensor POIL connector
(Internal defect) right. At this time, if
failure code is not Charge pressure
PIM connector
indicated, the device sensor
is defective. Atmospheric
PAMB connector
pressure sensor
Possible causes 3 Max. 1 z
(Disconnection or defective – each sensor (female) (+5 V) tance
and standard
contact of connector) Wiring harness between ENG (female) (47) Resis-
state – each sensor (female) (GND) tance
4 ness
Min. 1 Mz
– each sensor (female) and ground tance
Short circuit in wiring har- without turning starting switch ON.
(with another wiring harness) – each sensor (female) and between ENG Resis-
Min. 1 Mz
tance
(female) (47) – each sensor (female)
6 Defective engine controller 3) Turn starting switch ON.
ENG (male) Voltage
Between (37) and (47) 4.75 – 5.25V
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [CA234] (Engine overspeed) 1
Action code Failure code Engine overspeed

Trouble
Contents of
• Engine speed exceeded operating range.
trouble
Action of
• Reduce fuel injection rate until engine speed lowers in operating range.
controller
Problem that
appears on • Engine speed changes.
machine
Related • Engine speed can be checked by monitoring function (Code: 01002 (rpm)).
information • Method of reproducing failure code: Start engine and keep running at high idle.

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Possible causes
and standard The method of using the installed machine may be improper, so
2 Usage is improper
value in normal instruct the operator on how to use the machine properly.
state If causes 1 and 2 are not the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39
Failure code [CA238] (Ne speed sensor power supply error) 1
Action code Failure code Ne speed sensor power supply error

Trouble
Contents of
• Error occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of • Controls with signal from Bkup speed sensor.
controller • Limits output and continues operation.
Problem that • Engine output drops.
appears on • Engine stops during operation (when Bkup speed sensor is also defective)
machine • Engine cannot start during stop (when Bkup speed sensor is also defective)
Related
information

Disconnect device
Defective Ne speed sensor suggested on the
1
Ne speed sensor NE connector
failure code is not
indicated, the device
is defective.
2 Max. 1 z
(Disconnection or defective – NE (female) (1) tance
Max. 1 z
Possible causes – NE (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Grounding fault in wiring har-
3 ness Min. 1 Mz
– NE (female) (1) and ground tance
Min. 1 Mz
(with another wiring harness) – NE (female) (1) and between ENG Resis-
Min. 1 Mz
tance
(female) (48) – NE (female) (2)
5 Defective engine controller 3) Turn starting switch ON.
ENG (male) Voltage
Between (16) and (48) 4.75 – 5.25 V
40 HD465-7R, HD605-7R
HD465-7R, HD605-7R 41
Failure code [CA263] (Fuel temperature sensor high error) 1
Action code Failure code Fuel temperature sensor high error

Trouble
Contents of
• Fuel temperature sensor circuit is abnormally high.
trouble
Action of • Injection rate by fuel temperature sensor is compensated with coolant temperature sensor (If coolant
controller temperature sensor is abnormal, the controller sets to fixed value (95°C) and continues operation.)
Problem that
appears on
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 (°C)).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 (V)).

Defective fuel temperature without turning starting switch ON.
1
sensor (Internal defect) TFUEL (male) Fuel temperature Resistance
2 Max. 1 z
Possible causes (Disconnection or defective – TFUEL (female) (A) tance
– TFUEL (female) (B) tance
state
3 ness Min. 1 Mz
– TFUEL (female) (A) and ground tance
ENG (female) Fuel temperature Resistance
4 Defective engine controller Between
10 – 100°C 0.6 – 20 kz
(30) and (47)
42 HD465-7R, HD605-7R
HD465-7R, HD605-7R 43
Failure code [CA265] (Fuel temperature sensor low error) 1
Action code Failure code Fuel temperature sensor low error

Trouble
Contents of
• Fuel temperature sensor circuit is abnormally low.
trouble
Action of • Injection rate by fuel temperature sensor is compensated with coolant temperature sensor (If coolant
controller temperature sensor is abnormal, the controller sets to fixed value (95°C) and continues operation.)
Problem that
appears on
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 (°C)).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 (V)).

and standard
state
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45
Failure code [CA271] (PCV1 Short circuit) 1
Action code Failure code PCV1 short circuit

Trouble
Contents of
• Short circuit was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
• While engine is running, pulse voltage of about 70 V is applied to PCV1 (1) (if normal) and it cannot
information
be measured with circuit tester.

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit)
Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and ground Min. 1 Mz
2 ness Min. 1 Mz
PCV1 (female) (1) and ground tance
Possible causes Wiring harness between ENG (female) (5) – Resis-
Min. 1 Mz
and standard PCV1 (female) (2) and ground tance
value in normal 1) Turn starting switch OFF.
state 2) Connect T-adapter to connector PCV1.
Hot short in wiring harness
3 Wiring harness between ENG (female) (4) –
(Contact with 24 V circuit) Voltage Max. 1 V
PCV1 (female) (1)
Wiring harness between ENG (female) (5) –
Voltage Max. 1 V
PCV1 (female) (2)
4 Defective engine controller ENG (female) Resistance
Between (4) and (5) 2.3 – 5.3 z
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47
Failure code [CA272] (PCV1 Disconnection) 1
Action code Failure code PCV1 disconnection

Trouble
Contents of
• Disconnection was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump
1 PCV1 PCV1 (male) Resistance
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z
ness Wiring harness between ENG (female) (4) – Resis-
2 Max. 1 z
(Disconnection or defective PCV1 (female) (1) tance
Possible causes contact of connector) Wiring harness between ENG (female) (5) – Resis-
and standard Max. 1 z
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
3 ness Min. 1 Mz
Min. 1 Mz
Between (4) and (5) 2.3 – 5.3 z
48 HD465-7R, HD605-7R
HD465-7R, HD605-7R 49
Failure code [CA273] (PCV2 Short circuit) 1
Action code Failure code PCV2 short circuit

Trouble
Contents of
• Short circuit was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV2 (male) Resistance
1
PCV2 (Internal short circuit)
Between (1) and (2) 2.3 – 5.3 z
2 ness Min. 1 Mz
Possible causes Wiring harness between ENG (female) (10) Resis-
Min. 1 Mz
and standard – PCV2 (female) (2) and ground tance
state 2) Connect T-adapter to connector PCV2.
Hot short in wiring harness
3 Wiring harness between ENG (female) (9) –
(Contact with 24 V circuit) Voltage Max. 1 V
PCV2 (female) (1)
Voltage Max. 1 V
– PCV2 (female) (2)
Between (9) and (10) 2.3 – 5.3 z
50 HD465-7R, HD605-7R
HD465-7R, HD605-7R 51
Failure code [CA274] (PCV2 Disconnection) 1
Action code Failure code PCV2 disconnection

Trouble
Contents of
• Disconnection was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump without turning starting switch ON.
1 PCV2
PCV2 (male) Resistance
(Internal disconnection)
Between (1) and (2) 2.3 – 5.3 z
ness Wiring harness between ENG (female) (9) – Resis-
2 Max. 1 z
(Disconnection or defective PCV2 (female) (1) tance
Possible causes Max. 1 z
and standard – PCV2 (female) (2) tance
3 ness Min. 1 Mz
Min. 1 Mz
– PCV2 (female) (2) and ground tance
Between (9) and (10) 2.3 – 5.3 z
52 HD465-7R, HD605-7R
HD465-7R, HD605-7R 53
Failure code [CA322] (Injector #1 open/short error) 1
Action code Failure code Injector #1 system disconnection or short circuit

Trouble
Contents of
• Disconnection or short circuit was detected in injector #1 circuit.
trouble
Action of
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable
machine
Related
• While engine is running, pulse voltage of about 70 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Defective injector #1 INJ (male) Resistance
1
(Internal defect)
Between (1) and (12) 0.4 – 1.1 z
2 Max. 1 z
(Disconnection or defective – INJ (female) (1) tance
– INJ (female) (12) tance
and standard
3 ness Min. 1 Mz
– INJ (female) (1) and ground tance
Min. 1 Mz
Defective injector or wiring If failure code of multiple injector trouble is displayed, carry out trou-
4
harness of another cylinder bleshooting for that code, too.
Between (45) and (53) 0.4 – 1.1 z
54 HD465-7R, HD605-7R
HD465-7R, HD605-7R 55

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
• Speed does not become stable
machine
Related
information

1
(Internal defect)
Between (5) and (8) 0.4 – 1.1 z
2 Max. 1 z
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4
Between (46) and (60) 0.4 – 1.1 z
56 HD465-7R, HD605-7R
HD465-7R, HD605-7R 57

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
• Speed does not become stable.
machine
Related
information

1
(Internal defect)
Between (3) and (10) 0.4 – 1.1 z
Between (3), (10) – ground Min. 1 Mz
2 Max. 1 z
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4
Between (55) and (52) 0.4 – 1.1 z
58 HD465-7R, HD605-7R
HD465-7R, HD605-7R 59

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
(Internal defect)
Between (6) and (7) 0.4 – 1.1 z
2 Max. 1 z
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4
Between (57) and (59) 0.4 – 1.1 z
60 HD465-7R, HD605-7R
HD465-7R, HD605-7R 61

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
(Internal defect)
Between (2) and (11) 0.4 – 1.1 z
2 Max. 1 z
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4
Between (54) and (51) 0.4 – 1.1 z
62 HD465-7R, HD605-7R
HD465-7R, HD605-7R 63

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
(Internal defect)
Between (4) and (9) 0.4 – 1.1 z
2 Max. 1 z
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4
Between (56) and (58) 0.4 – 1.1 z
64 HD465-7R, HD605-7R
HD465-7R, HD605-7R 65
Failure code [CA342] (Calibration code inconsistency) 1
Action code Failure code Engine controller data inconsistency

Trouble
Contents of
• Data inconsistency occurred in engine controller.
trouble
Action of
controller
Problem that
appears on
stopped state.
machine
Related
information

and standard
state
Failure code [CA351] (Injectors drive circuit error) 1
Action code Failure code Injector drive circuit error

Trouble
Contents of
• Error was detected in injector drive circuit.
trouble
Action of • Limits output for travel (Limits common rail pressure)
Problem that
machine
Related
information

Possible causes
Check the failure code (injector system error code) that is displayed
and standard
1 Defect in related system at the same time. If another code is displayed, carry out trouble-
value in normal
shooting for it.
state
Carry out troubleshooting for failure code [CA111].
66 HD465-7R, HD605-7R
Failure code [CA352] (Sensor power supply 1 low error) 1
Action code Failure code Sensor power supply 1 low error

Trouble
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of
• Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
controller
Problem that
machine
Related
information

and standard
state
HD465-7R, HD605-7R 67
Failure code [CA386] (Sensor power supply 1 high error) 1
Action code Failure code Sensor power supply 1 high error

Trouble
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of
• Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
controller
Problem that
machine
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Disconnect device
Defective sensor Common rail
suggested on the PFUEL
2 pressure sensor
failure code is not
indicated, the device Ne speed sensor NE connector
is defective.
Max. 1 z
Disconnection in wiring har- – PFUEL (female) (1) tance
3 Max. 1 z
(Disconnection or defective and NE (female) (1) – chassis ground tance
– PFUEL (female) (3) tance
and standard
– NE (female) (2) tance
state
Min. 1 Mz
– PFUEL (female) (1) and ground tance
4 ness Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Short circuit in wiring har- Wiring harness between ENG (female) (25)
Resis-
5 ness – PFUEL (female) (2) and between ENG Min. 1 Mz
tance
(with another wiring harness) (female) (except 25) – each sensor (female)
Min. 1 Mz
– NE (female) (3), ENG (female) (except 27) tance
68 HD465-7R, HD605-7R

Possible causes 2) Connect T-adapter to connector ENG.
and standard 3) Turn starting switch ON.
value in normal 6 Defective engine controller
state ENG Voltage
Between (16) – (48) and
4.75 – 5.25 V
(33) – (47)
HD465-7R, HD605-7R 69

© 2007 KOMATSU
All Rights Reserved
70 HD465-7R, HD605-7R
SEN02536-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [CA431] (Trouble in idle validation switch) ................................................................................. 4
Failure code [CA432] (Idle validation action error).......................................................................................... 6
Failure code [CA441] (Battery voltage low error) ............................................................................................ 6
Failure code [CA442] (Battery voltage high error) .......................................................................................... 7
Failure code [CA449] (Common rail pressure high error 2) ............................................................................ 7
Failure code [CA451] (Common rail pressure sensor high error) ................................................................... 8
Failure code [CA452] (Common rail pressure sensor low error)................................................................... 10
Failure code [CA553] (Common rail pressure high error 1) ...........................................................................11
Failure code [CA554] (Common rail pressure sensor: In-range error).......................................................... 12
Failure code [CA559] (Supply pump pressure very low error) ...................................................................... 13
Failure code [CA689] (Engine Ne speed sensor error)................................................................................. 16
Failure code [CA731] (Engine Bkup speed sensor phase error) .................................................................. 18
Failure code [CA757] (All continuous data lost error) ................................................................................... 19
Failure code [CA778] (Engine Bkup speed sensor error) ............................................................................. 20
Failure code [CA1633] (KOMNET datalink timeout error)............................................................................. 22
Failure code [CA2185] (Throttle sensor supply voltage high error) .............................................................. 24
HD465-7R, HD605-7R 1
Failure code [CA2186] (Throttle sensor power supply low error).................................................................. 26

Failure code [CA2249] (Supply pump pressure very low error 2) ................................................................. 27
Failure code [CA2555] (Intake heater relay voltage low error)...................................................................... 28
Failure code [CA2556] (Intake heater relay voltage high error) .................................................................... 30
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Failure code [CA431] (Trouble in idle validation switch) 1

Action code Failure code Trouble in idle validation switch
Trouble
Contents of
• Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit.
trouble
Action of
• Operates normally according to throttle sensor (E01 Testing and maintenance)
controller
Problem that
machine
Related
information

and carry out troubleshooting.
AS1 Signal name Voltage
Defective accelerator pedal Between (5) – (4) Signal 1
1 See Fig. 1
(Internal defect) Between (6) – (4) Signal 2
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between J2P (female) (32) – Resis-
Max. 1 z
ness (Disconnection in wiring AS1 (female) (4) tance
2
or defective contact in con- Wiring harness between J2P (female) (11) – Resis-
nector) Max. 1 z
Max. 1 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between J2P (female) (32) – Resis-
state Grounding fault in wiring Min. 1 Mz
3 harness (Short circuit with
ground circuit) Wiring harness between J2P (female) (11) – Resis-
Min. 1 Mz
Min. 1 Mz
Wiring harness between J2P (female) (32) –
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4)
4
24V circuit) in wiring harness Wiring harness between J2P (female) (11) –
Voltage Max. 1 V
AS1 (female) (5)
Wiring harness between J2P (female) (1) –
Voltage Max. 1 V
AS1 (female) (6)
5 Defective engine controller J2P Signal name Voltage
Between (11) – (32) Signal 1
See Fig. 1
Between (1) – (32) Signal 2
4 HD465-7R, HD605-7R
Fig. 1
Pedal: Stroke of accelerator pedal
Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1
and switch 2
HD465-7R, HD605-7R 5
Failure code [CA432] (Idle validation action error) 1
Action code Failure code Idle validation action error

Trouble
Contents of
• Action error was detected in idle validation switch circuit.
trouble
Action of
• Operates at position of throttle of accelerator pedal (throttle sensor).
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: 18300).
Related
• The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring func-
information
tion (Code: 18301).

and standard
state
Failure code [CA441] (Battery voltage low error) 1
Action code Failure code Battery voltage low error

Trouble
Contents of
• Low voltage was detected in battery voltage circuit.
trouble
Action of
controller
Problem that
appears on
stopped state.
machine
Related
information

and standard
state
6 HD465-7R, HD605-7R
Failure code [CA442] (Battery voltage high error) 1
Action code Failure code Battery voltage high error

Trouble
Contents of
• High voltage was detected in battery voltage circuit.
trouble
Action of
controller
Problem that
appears on
stopped state.
machine
Related • Method of reproducing failure code: Turn the starting switch ON.
information • Source voltage of engine controller can be checked with monitoring function (Code: 03200).

and standard
state
Failure code [CA449] (Common rail pressure high error 2) 1
Action code Failure code Common rail pressure high error 2

Trouble
Contents of • Common rail pressure sensor circuit detected abnormally high level (Pressure exceeded set maxi-
trouble mum level).
Action of
• Limits output and continues operation (limits common rail pressure).
controller
Problem that
appears on • Engine output lowers.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400 (MPa)).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information

and standard
state
HD465-7R, HD605-7R 7
Failure code [CA451] (Common rail pressure sensor high error) 1
Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally high.
trouble
Action of
• Limits output for travel (Limits common rail pressure)
controller
Problem that
machine
Related
information

Defective common rail pres- If failure code [CA352] or [CA386] is also indicated, carry out trou-
1
sure sensor power system bleshooting for it first.
PFUEL Voltage
Defective common rail pres- Between (1) and (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal defect) Between (2) and (3) Signal 0.25 – 4.6 V
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Disconnection in wiring har- Wiring harness between ENG (female) (33) Resis-
ness Max. 1 z
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between ENG (female) (25) Resis-
Max. 1 z
tor) – PFUEL (female) (2) tance
Max. 1 z
4 Min. 1 Mz
(Short circuit with ground – PFUEL (female) (1) and ground tance
circuit) Wiring harness between ENG (female) (25) Resis-
Min. 1 Mz
8 HD465-7R, HD605-7R

Resis-
– PFUEL (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (25) – PFUEL (female) (2)
(with another wiring harness) – PFUEL (female) (1) and between ENG Resis-
tance
and standard (female) (47) – PFUEL (female) (3)
value in normal Wiring harness between ENG (female) (25)
Resis-
state – PFUEL (female) (2) and between ENG Min. 1 Mz
tance
(female) (47) – PFUEL (female) (3)
6 Defective engine controller ENG Voltage
Between (33) and (47) 4.75 – 5.25 V
Between (25) and (47) 0.25 – 4.6 V
HD465-7R, HD605-7R 9
Failure code [CA452] (Common rail pressure sensor low error) 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
10 HD465-7R, HD605-7R
Failure code [CA553] (Common rail pressure high error 1) 1
Action code Failure code Common rail pressure high error 1

Trouble
Contents of • Common rail pressure sensor circuit detected abnormally high level
trouble (Pressure kept higher than set level beyond expectation for 10 seconds).
Action of
controller
Problem that
appears on
machine
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly. (Viscosity is high)
Defective electrical system of Electrical system of common rail pressure sensor may be defective.
3
Possible causes common rail pressure sensor Carry out troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal Mechanical system of common rail pressure sensor may be defec-
4 of common rail pressure sen-
state tive. Check it directly.
sor
Spring damage, seat wear, or ball stuck of overflow valve is sus-
5 Defective overflow valve
pected. Check it directly.
6 Clogged overflow pipe Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.
HD465-7R, HD605-7R 11
Failure code [CA554] (Common rail pressure sensor: In-range error) 1
Action code Failure code Common rail pressure sensor: In-range error
Trouble
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
12 HD465-7R, HD605-7R
Failure code [CA559] (Supply pump pressure very low error) 1
Action code Failure code Supply pump pressure very low error
Trouble
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check
of pressure in fuel low pressure circuit, see Testing and adjusting,
Defect in low pressure cir- “Testing fuel pressure”.
3
cuit parts
Pressure in fuel low-pressure Min. 0.15 MPa
circuit {Min. 1.5 kg/cm2}
4 Clogged fuel filter, strainer a For more information on troubleshooting, see Note 2.
Electrical system of supply pump PCV may be defective. Carry out
Defective electrical system of
5 troubleshooting for failure code [CA271], [CA272], [CA273], or
supply pump PCV
[CA274].
Defective common rail pres- Mechanical system of common rail pressure sensor may be defec-
6
Possible causes sure sensor tive. Check whether wiring harness is damaged.
and standard a For check of leakage through pressure limiter, see Testing and
value in normal adjusting, “Testing fuel return rate and leakage”.
state 7 Defective pressure limiter
Max. 10 cc/min
Leakage through pressure limiter
(at full stall or relief)
a For check of limited return rate (spill) from injector, see Testing
and adjusting, “Testing fuel return rate and leakage”.
Speed at rated operation Limited return (spill) rate
(stall load) from injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not the cause of the trouble, supply pump may
9 Defective supply pump
be defective.
<Using check sheet>

While carrying out troubleshooting above, record troubleshooting contents on the “Check sheet for no-pres-
sure feed” attached separately.
HD465-7R, HD605-7R 13
Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q Clogged fuel filter
q Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
14 HD465-7R, HD605-7R
Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 750 ± 50
01002 Engine speed High idle rpm 2,270 ± 50
Full stall (P-mode) rpm 1,910 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 160
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 1,200}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent 1,600 rpm cc/min 960 Speed:
Rating or equivalent 1,700 rpm cc/min 1,020
12 Return rate from injector Rating or equivalent 1,800 rpm cc/min 1,080 Return rate:
HD465-7R, HD605-7R 15
Failure code [CA689] (Engine Ne speed sensor error) 1
Action code Failure code Engine Ne speed sensor error

Trouble
Contents of
• Error was detected in engine Ne speed sensor circuit.
trouble
Action of
• Operates the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
information

Defective sensor power sup- If failure code [CA238] is displayed, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
Max. 1 z
tor) – NE (female) (2) tance
Max. 1 z
Grounding fault in wiring har- Wiring harness between ENG (female) (16) Resis-
Min. 1 Mz
ness – NE (female) (1) and ground tance
3
(Short circuit with ground Wiring harness between ENG (female) (48) Resis-
Possible causes circuit) Min. 1 Mz
and standard
value in normal Min. 1 Mz
state
Resis-
– NE (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
(with another wiring harness) – NE (female) (1) and between ENG Resis-
Min. 1 Mz
tance
Resis-
– NE (female) (2) and between ENG Min. 1 Mz
tance
If causes 1 – 4 are not the cause of the trouble, engine Ne speed
Defective engine Ne speed
5 sensor may be defective. (Since trouble is in system, troubleshoot-
sensor
ing cannot be carried out.)
If causes 1 – 5 are not the cause of the trouble, engine controller
6 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17
Failure code [CA731] (Engine Bkup speed sensor phase error) 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of • There is phase error in engine Bkup speed sensor circuit.
trouble (Bkup speed sensor signal and Ne speed sensor signal are out of phase.)
Action of
• Controls the engine with signal from engine Ne speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
a If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced.
information
(See "Disassembly and assembly", "Removal and installation of fuel supply pump".)

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
18 HD465-7R, HD605-7R
Failure code [CA757] (All continuous data lost error) 1
Action code Failure code All continuous data lost error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
information

and standard
state
HD465-7R, HD605-7R 19
Failure code [CA778] (Engine Bkup speed sensor error) 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
• Error was detected in engine Bkup speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Ne speed sensor.
controller • Limits output and continues operation.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
a If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced.
information
(See "Disassembly and assembly", "Removal and installation of fuel supply pump".)

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
ness Max. 1 z
– G (female) (A) tance
Max. 1 z
tor) – G (female) (B) tance
Max. 1 z
– G (female) (C) tance
3 Min. 1 Mz
(Short circuit with ground – G (female) (A) and ground tance
Possible causes circuit) Wiring harness between ENG (female) (26) Resis-
and standard Min. 1 Mz
– G (female) (C) and ground tance
value in normal
state Wiring harness between ENG (female) (37)
Resis-
4 Defective resistance (RES) – G (female) (A) and between ENG (female) 620 z
tance
(26) – G (female) (C)
Short circuit in wiring har- Resis-
– G (female) (A) and between ENG (female) Min. 1 Mz
5 ness tance
(47) – G (female) (B)
(with another wiring harness)
Resis-
– G (female) (B) and between ENG (female) Min. 1 Mz
tance
(26) – G (female) (C)
If causes 1 – 4 are not the cause of the trouble, engine Bkup speed
Defective engine Bkup
6 sensor may be defective. (Since trouble is in system, troubleshoot-
speed sensor
ing cannot be carried out.)
If causes 1 – 4 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [CA1633] (KOMNET datalink timeout error) 1
Action code Failure code KOMNET datalink timeout error

Trouble
Contents of
• There is error in KOMNET communication circuit with applicable machine.
trouble
Action of
• Operates in default mode or holds the state set when error occurred.
controller
Problem that
appears on
machine
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [DB2RKR].
state
22 HD465-7R, HD605-7R
HD465-7R, HD605-7R 23
Failure code [CA2185] (Throttle sensor supply voltage high error) 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• Voltage of throttle sensor power supply (5V) circuit is high.
trouble
Action of
controller
Problem that
appears on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
Related
information

Disconnect device
Defective accelerator pedal suggested on the
1
Accelerator pedal AS1 connector
failure code is not
indicated, the device
is defective.
ness Wiring harness between J2P (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective AS1 (female) (1) tance
contact of connector) Wiring harness between J2P (female) (23) – Resis-
and standard
3 ness Min. 1 Mz
Min. 1 Mz
4 ness Wiring harness between J2P (female) (22) –
(with another wiring harness) AS1 (female) (1) and J2P (female) (23) – Resis-
Min. 1 Mz
tance
AS1 (female) (3)
J2P Voltage
Between (22) and (23) 4.75 – 5.25 V
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [CA2186] (Throttle sensor power supply low error) 1
Action code Failure code Throttle sensor power supply low error
Trouble
Contents of
• Voltage of throttle sensor power supply (5V) circuit is low.
trouble
Action of
controller
Problem that
appears on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
Related
information

and standard
state
26 HD465-7R, HD605-7R
Failure code [CA2249] (Supply pump pressure very low error 2) 1
Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
• There is no-pressure feed error (level 2) in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
HD465-7R, HD605-7R 27
Failure code [CA2555] (Intake heater relay voltage low error) 1
Action code Failure code Intake heater relay voltage low error
Trouble
Contents of
• Disconnection error was detected in intake air heater relay circuit.
trouble
Action of
• Automatic preheating (to be started when engine coolant temperature is below -5 °C) is not started.
controller
Problem that
machine
Related
information

and standard
state
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [CA2556] (Intake heater relay voltage high error) 1
Action code Failure code Intake heater relay voltage high error
Trouble
Contents of
• Short circuit was detected in intake heater relay circuit.
trouble
Action of
• Automatic preheating (to be started when engine coolant temperature is below -5 °C) is not started.
controller
Problem that
machine
Related
information

Defective intake heater relay without turning starting switch ON.
1
(Internal defect) R37 (male) Resistance
Between (1) and (2) 200 – 400 z
ness Wiring harness between J2P (female) (40) – Resis-
2 Max. 1 z
(Disconnection or defective R37 (female) (1) tance
contact of connector) Wiring harness between J2P (female) (42) – Resis-
and standard R37 (female) (2) tance
3 ness Min. 1 Mz
R37 (female) (1) and ground tance
Min. 1 Mz
R37 (female) (2) and ground tance
4 Defective engine controller J2P Heater relay Voltage
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31

© 2007 KOMATSU
All Rights Reserved
32 HD465-7R, HD605-7R
SEN02537-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
40 Troubleshooting
Failure code [D19HKB] (Stop lamp relay output system: Short circuit)........................................................... 3
Disconnection, short circuit or short circuit to power sorce line) .............................................................. 4
Failure code [DAF9KM] Wrong connection of connector ................................................................................ 6
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor):
Abnormal communication) ....................................................................................................................... 8
Lowering of source voltage)................................................................................................................... 10
Abnormality in controller) ....................................................................................................................... 12
Failure code [DAQ2KK] (Transmission controller solenoid power source:
Power source voltage too low)............................................................................................................... 13
Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection) ................................. 14
Failure code [DAQRKR] (Abnormality in CAN communication (Transmission)) ........................................... 14
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ............................................ 15
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)........................ 15
HD465-7R, HD605-7R 1

Power source system trouble) ............................................................................................................... 16
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 20
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled) ................... 22
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) ............................................. 24
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ..................... 26
Failure code [DBBRKR] (Abnormality in CAN communication (VHMS))....................................................... 29
Failure code [DBC2KK] (ABS controller solenoid power source: Power source system trouble) ................. 30
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)................................................. 34
Failure code [DBCRKR] (Abnormality in CAN communication (ABS)).......................................................... 34
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................................... 35
Out of input signal range)....................................................................................................................... 36
Failure code [DDD8KA] (ARSC system switch system: Disconnection) (If equipped).................................. 38
Failure code [DDD8KB] (ARSC system switch system: Short circuit) (If equipped) ..................................... 40
Failure code [DDD9KA] (ABS system switch system: Disconnection).......................................................... 42
Failure code [DDD9KB] (ABS system switch system: Short circuit) ............................................................. 44
Failure code [DDDAKA] (ASR system switch: Disconnection)...................................................................... 46
Failure code [DDDAKB] (ASR system switch: Short circuit) ......................................................................... 48
Failure code [DDP6L4] (Service brake pressure switch trouble (Rear)) ....................................................... 50
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) ....................................................................... 52
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)........................................................................ 54
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) ...................................................................... 56
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) ..................................................................... 58
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) ..................................................................... 60
Failure code [DDTNKA] (R clutch fill switch: Disconnection) ........................................................................ 62
Failure code [DDTPKA] (4th clutch fill switch: Disconnection) ...................................................................... 64
Failure code [DF10KA] (Gear shift lever: Disconnection) ............................................................................. 66
Failure code [DF10KB] (Gear shift lever: Short circuit) ................................................................................. 69
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range) .......................... 72
Failure code [DGR2KZ] (Retarder oil temperature sensor system trouble : Ground fault (Rear wheel)) ...... 74
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................................... 76
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ..................... 78
2 HD465-7R, HD605-7R
Failure code [D19HKB] (Stop lamp relay output system: Short circuit) 1
Action code Failure code Stop lamp relay output system: Short circuit
Trouble
E01 D19HKB (Retarder controller system)
Contents of
• When signal was output to stop lamp relay, abnormal current flowed.
trouble
Action of • Turns output to stop lamp relay OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Stop lamp does not light up.
machine
Related
information

2) Connect T-adapter to connector R08 (male).
R08 (male) Resistance
1 Defective stop lamp relay Between (1) – (2) 250 – 350 z
Between (1) – ground Min. 1 Mz
Relay may be checked by exchanging it with another relay
(5-pole relay).
Possible causes
value in normal Grounding fault in wiring har- 2) Disconnect connectors BRC2 and R08.
state 2 ness 3) Connect T-adapter to BRC2 (female).
(Contact with ground circuit) Wiring harness between BRC2 (female) Resis-
Min. 1 Mz
(18) – R08 (female) (2) and ground tance
2) Insert T-adapter in connector BRC2 (female).
3 Defective retarder controller BRC2 Brake pedal Voltage
Between (18) – When pressed Max. 1 V
ground When in neutral 20 – 30 V
HD465-7R, HD605-7R 3

Disconnection, short circuit or short circuit to power sorce line) 1
Action code Failure code Front brake cut-off solenoid valve: Disconnection, short circuit
Trouble
E01 D5ZKKZ (Retarder controller system)
Contents of
• No current or overcurrent flowed in front brake cut-off solenoid valve circuit.
trouble
Action of • If wiring harness has disconnection, no current flows.
controller • If wiring harness has short circuit, controller stops output to solenoid.
Problem that
• Front brake cannot be cut off. (when disconnection)
appears on
machine • Front brake cut off. (when short circuit to power sorce line)
Related
information

2) Connect T-adapter to connector S03 (male).
Defective front brake cut-off S03 (male) Resistance
1
solenoid valve
Between (1) – (2) 20 – 40 z
(1), (2) – ground Min. 1 Mz
Disconnection in wiring har- 2) Connect T-adapter to connectors BRC3 (female) and S03
ness (female).
2 (Disconnection in wiring or Wiring harness between BRC3 (female) Resis-
Max. 1 z
defective contact in connec- (28) – S03 (female) (1) tance
tor) Wiring harness between BRC3 (female) Resis-
Max. 1 z
(13) – S03 (female) (2) tance
2) Disconnect connectors BRC3 and S03.
3) Connect T-adapter to BRC3 (female).
Possible causes
and standard Grounding fault in wiring har- Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
value in normal 3 ness (28) – S03 (female) (1) and ground tance
state (Contact with ground circuit) Contact of wiring harness between BRC3
(female) (28) – S03 (female) (1) and wiring Resis-
Min. 1 Mz
harness between BRC3 (female) (13) – S03 tance
(female) (2)
2) Connect T-adapter in connector BRC3.
Hot short (Contact with 24V 3) Turn starting switch ON.
4 4) Turn front brake cut switch OFF.
circuit) in wiring harness
Wiring harness between BRC3 (female)
Voltage Max. 1 V
(28) – S03 (female) (1)
2) Connect T-adapter in connector BRC3.
5 Defective retarder controller Front brake cut-off
BRC3 Voltage
switch
When operated (cut) 20 – 30 V
Between (28) – (13)
When not operated Max. 1 V
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [DAF9KM] Wrong connection of connector 1

Action code Failure code Wrong connection of connector
Trouble
E03 DAF9KM (Machine monitor system)
Contents of
• Check signal of connector is different from internal setting of machine monitor.
trouble
Action of • Detects only at start.
machine monitor • Keeps trouble condition until starting switch is turned OFF.
Problem that
• Machine monitor mode selector switch cannot be selected.
appears on
• Headlamp high beam pilot lamp, turn signal pilot lamp, and output mode pilot lamp do not operate.
machine
Related
information

Wrong connection of connec- Connector DPC2A (female) may be connected to DPC3A (male)
1
tor by mistake. Check and connect it correctly, if connected wrongly.
1) Starting switch OFF.
Disconnection in wiring har- 2) Connect T-adapter to DPC2A.
Possible causes ness (Disconnection in wiring 3) Turn starting switch ON
2
and standard or defective contact in con-
DPC2A Voltage
value in normal nector)
state Between (5) – ground 20 – 30 V
Short circuit in wiring har- ing without turning starting switch ON.
3 ness (with another wiring
harness) Between DPC3A (female) (5) – pin other Resis-
Min. 1 Mz
than DPC3A (5) tance
4 Defective machine monitor Check by replacing machine monitor.
6 HD465-7R, HD605-7R
HD465-7R, HD605-7R 7
Failure code [DAFRKR] (Abnormal CAN communication

(machine monitor): Abnormal communication) 1
Action code Failure code Abnormal CAN communication (machine monitor): Abnormal com-
Trouble munication
E03 DAFRKR (Machine monitor system)
Contents of
• Transmission controller stops updating the data received from the machine monitor.
trouble
Action of • Keep the information at the time when abnormality occurred.
controller • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
• When the network is abnormal, the machine monitor can not correctly display the data from each
appears on
controller.
machine
Related
• Check that the power source circuit of machine monitor is normal.
information

2) Disconnect related connectors (See circuit diagram).
3) Connect T-adapter to connector of circuit to be measured.
Defective CAN terminal
1 Between CAN2 (male) (A) – (B) (Engine Resis-
resistance 120 ± 12 z
side) tance
Between CAN2 (male) (A) – (B) (Inner cab) Resis- 120 ± 12 z

tance
Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
(8) – CAN2 (female) (A), (B) tance
(8) – BRC2 (female) (32), (22) tance
(8) – ATC2 (female) (32), (22) tance
Disconnection in wiring Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
harness (8) – J2P (female) (46), (47) tance
2
(Disconnection or defective Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
Possible causes
contact) (8) – DL (male) (3), (10) tance
and standard
value in normal Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
state (8) – CAN2 (female) (A), (B) tance
Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
Max. 1 z
(8) – ABS9 (female) (9), (10) tance
Wiring harness between J2P (female) (46), Resis-
(47) – CAN2 (female) (A), (B) – CAN2 Max. 1 z
tance
(female) (A), (B)
Between ground and wiring harness between Resis- Min. 1 Mz
DPC4 (female) (3) – CAN2 (female) (A) tance
Short circuit of harness Between ground and wiring harness between Resis- Min. 1 Mz
3
(Contact with ground circuit) DPC4 (female) (3) – BRC2 (female) (32) tance
DPC4 (female) (3) – ATC2 (female) (32) tance
DPC4 (female) (3) – J2P (female) (46) tance
8 HD465-7R, HD605-7R

DPC4 (female) (3) – DL (male) (3) tance
Max. 1 z
Short circuit of harness (8) – CAN1 (female) (A), (B) tance
3 (Contact with ground circuit) Wiring harness between DPC4 (female) (3), Resis-
and standard
value in normal Between ground and wiring harness between Resis-
J2P (female) (46) – CAN2 (female) (A) – Min. 1 Mz
state tance
CAN2 (female) (A)
Defective machine monitor,
engine controller, If no problem is found in causes 1 – 3, machine monitor, engine
transmission controller or controller, transmission controller and retarder controller, VHMS,
4
retarder controller, VHMS, PLM controller and ABS controller can be suspected to be defec-
PLM controller and ABS con- tive (since this is an internal defect, it cannot be diagnosed).
troller
HD465-7R, HD605-7R 9

Lowering of source voltage) 1
Action code Failure code Transmission controller direct power supply: Lowering of source
Trouble voltage
E03 DAQ0KK (Transmission controller system)
Contents of
• While engine was running, controller direct power supply circuit voltage lowered below 18 V.
trouble
Action of • Keeps current gear speed.
controller • If gearshift lever is set in N, transmission is set in neutral.
• If there is not power supply voltage (there is disconnection), transmission is set in neutral suddenly
Problem that during travel and machine cannot restart until voltage becomes normal.
appears on • The gear is set in Neutral suddenly during travel and the machine cannot start again until the volt-
machine age rises to the normal level.
• If power supply voltage is low, machine can move but transmission may slip because of load.
• If failure code "AB00MA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related
information • If the fuse is broken, check the line between the fuse and ATC3 (female) (1) and (11) for grounding
fault.

a Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Defective battery
Specific
Specific gravity of battery fluid Min. 1.26
gravity
2) Disconnect negative (–) terminal of battery and insert T-adapter
in ATC3.
3) Connect negative (–) terminal of battery.
Between battery relay terminal B – ground Voltage 20 – 30 V
Disconnection in wiring har- Between ATC3 (1), (11) – ground Voltage 20 – 30 V
Possible causes ness
2 If there is voltage between battery relay terminal B and ground and
and standard (Disconnection or defective there is not voltage between ATC3 (1) and (11), wiring harness
value in normal contact) between them has disconnection.
state
2) Disconnect negative (–) terminal of battery and connect T-
adapter to ATC3 (female)
Wiring harness between ATC3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground tance
in ATC3.
Defective transmission con- 3) Connect negative (–) terminal of battery.
3
troller 4) Turn starting switch ON.
Between ATC3 (1), (11) – (21), (31), (32),
Voltage 20 – 30 V
(33)
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11

Abnormality in controller) 1
Action code Failure code Transmission controller nonvolatile memory: Abnormality in con-
Trouble
E01 DAQ0KT troller (Transmission controller system)
• An abnormality has occurred in the nonvolatile memory inside the controller.

Contents of
trouble • Just after starting switch was turned OFF, there was not battery direct power supply and finishing
operation was not carried out normally.
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine control parameter may change and transmission gear shift shock may get worse.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard Since this is an internal defect, it cannot be diagnosed.
value in normal Defective transmission
1 (It is no problem to keep using controller unless any visible trouble
state controller
symptom appears on machine.)
12 HD465-7R, HD605-7R
Failure code [DAQ2KK] (Transmission controller solenoid power

source: Power source voltage too low) 1
Action code Failure code Transmission controller solenoid power source: Power source volt-
Trouble
E03 DAQ2KK age too low (Transmission controller system)
Contents of • Battery direct power source voltage of transmission controller has dropped to above 20 V, and
trouble solenoid power source voltage has dropped to below 18 V.
Action of • Holds the gear speed.
controller • Keeps neutral with shift lever neutral.
Problem that
appears on • Suddenly shifts to neutral while traveling, and the machine cannot move off again.
machine
Related
• When the fuse is blown, check for ground fault of line from fuse – ATC3 (female) (2), (12), (22).
information

in ATC3.
harness
1 Between battery relay terminal M – ground Voltage 20 – 30 V
Possible causes contact) Between ATC3 (2), (12), (22) – ground Voltage 20 – 30 V
and standard If there is voltage between battery relay terminal M and ground and
value in normal there is not voltage between ATC3 (2), (12), (22) and ground, wir-
state ing harness between them has disconnection.
in ATC3.
Defective transmission 3) Connect negative (–) terminal of battery.
2
controller 4) Turn starting switch ON.
Between ATC3 (2), (12), (22) – (21), (31),
Voltage 20 – 30 V
(32), (33)
HD465-7R, HD605-7R 13
Failure code [DAQ9KQ] (Transmission controller: Disagreement of

model selection) 1
Action code Failure code Transmission controller: Disagreement of model selection
Trouble
E03 DAQ9KQ (Machine monitor system)
Contents of • Machine model information from machine monitor is different from machine model information
trouble saved in transmission controller.
Action of
• Lights up central warning lamp and sounds alarm buzzer.
machine monitor
Problem that
appears on • Machine cannot travel.
machine
Related
information

Failure code [DAQ9KQ] is not displayed (Code is not displayed).
Possible causes Wrong setting of machine
1 a When machine monitor or transmission controller is replaced,
and standard model by machine monitor
set them according to Testing and adjusting.
value in normal
state Controller of correct part No. is mounted.
Installation of wrong trans-
2 a Check part No. If it is wrong, replace transmission controller
mission controller
with correct one.
Failure code [DAQRKR] (Abnormality in CAN communication (Trans-

mission)) 1
Action code Failure code Abnormality in CAN communication (Transmission)
Trouble
E03 DAQRKR (Transmission controller system)
Contents of • Machine monitor cannot obtain information from transmission controller through CAN communica-
trouble tion circuit.
Action of
• Keeps information at time of occurrence of abnormality.
controller
Problem that
• System may not operate normally.
appears on
machine • Information from transmission controller is not displayed.
Related
information

and standard
value in normal Carry out troubleshooting for failure code [DAFRKR]
state
14 HD465-7R, HD605-7R
Failure code [DAQRMA] (Transmission controller option setting:

Malfunction) 1
Action code Failure code Transmission controller option setting: Malfunction
Trouble (Machine monitor-transmission controller)
E03 DAQRMA (Machine monitor system)
Contents of • Option setting signals inputted from machine monitor with the starting switch ON are different from
trouble the option settings that controller memorizes.
• Holds the gear speed in neutral.
Action of
• Controls with the option setting that the controller memorizes.
machine monitor
• It does not return normal unless the starting switch is turned OFF.
Problem that
appears on • The gear speed becomes neutral and the machine cannot move off again.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard
value in normal Defective option setting of machine monitor or internal defect of
state monitor
Failure code [DB10KT] (Retarder controller nonvolatile memory:

Abnormality in controller) 1
Action code Failure code Retarder controller nonvolatile memory: Abnormality in controller
Trouble
E01 DB10KT (Retarder controller system)
Contents of
• An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine parameter may change and power may increase or decrease.
machine
Related
information

and standard
value in normal Since this is an internal defect, it cannot be diagnosed.
state Replace to controller.
HD465-7R, HD605-7R 15

Power source system trouble) 1
Action code Failure code Retarder controller solenoid power source: Power source system
Trouble trouble
E03 DB12KK (Retarder controller system)
Contents of • While controller direct power source voltage is normal, solenoid power source voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power source.
Problem that • All systems of retarder controller do not operate. (retarder, dump, automatic suspension, ARSC and
appears on ASR)
machine • Failure code (DHU2KX and DHU3KX) are displayed at the same time.
• If the fuse is blown, check for ground fault of line from fuse – BRC3 (female) (2), (12), (22).
Related
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, carry
out troubleshooting for it first.

in BRC3.
Between battery terminal M – ground Voltage 20 – 30 V
Between BRC3 (2), (12), (22) – ground Voltage 20 – 30 V
harness If voltage at fuse BT3 (12) is normal and voltage at BRC3 (2), (12),
1 (22) is abnormal, wiring harness between fuse (12) – BRC3
Possible causes contact) (female) (2), (12), (22) has disconnection.
value in normal 2) Disconnect negative (–) terminal of battery and connect T-
state adapter to BRC3 (female).
Wiring harness between BRC3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground tance
in BRC3.
2 Defective retarder controller 3) Connect negative (–) terminal of battery.
Between BRC3 (2), (12), (22) – ground Voltage 20 – 30 V
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17

Power source voltage too low) 1
Action code Failure code Retarder controller battery direct power source: Power source volt-
Trouble age too low
E03 DB13KK (Retarder controller system)
Contents of
• Controller source voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • Retarder does not operate.
machine
• When the fuse is blown, check the short circuit of line from fuse – BRC3 (female) (1), (11), (2), (12),
Related (22).
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, carry

a Check battery voltage and electrolyte specific gravity.
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
2) Disconnect battery (–) terminal and connect T-adapter to BRC3
(female).
Max. 1 z
(21), (31), (32), (33) – ground tance
Disconnection in wiring har- 2) Disconnect battery (–) terminal and insert T-adapter in BRC3
Possible causes
ness (female).
and standard
2 (Disconnection in wiring or 3) Connect battery (–) terminal.
value in normal
state defective contact in connec- Between battery relay terminal B – ground Voltage 20 – 30 V
tor) Between BRC (1), (11) – ground Voltage 20 – 30 V
2) Disconnect battery (–) terminal and connect T-adapter to BRC3
(female).
If there is voltage between battery relay terminal B and ground but
not between ATC3 (1), (11) and ground, wiring harness or fuse is
broken.
2) Disconnect battery (–) terminal and insert T-adapter in BRC3
Defective transmission con- (female).
3
troller 3) Connect battery (–) terminal.
Between BRC3 (1), (11) – ground Voltage 20 – 30 V
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [DB19KQ] Disagreement of model selection (Retarder

controller) 1
Action code Failure code Disagreement of model selection (Retarder controller)
Trouble
E03 DB19KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in retarder controller.
Action of • Turns all outputs OFF at retarder controller.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • When operator performs starting operation, machine does not start.
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.
information • Method of reproducing failure code: Turn starting switch ON.

Failure code [DB19KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
machine monitor After replacing machine monitor or retarder controller, set them
value in normal
correctly according to Testing and adjusting volume.
state
Wrong reterder controller may be installed. Check its part No. and
install correct reterder controller.
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [DB1RKR] (CAN communication (retarder controller):

Communication disabled) 1
Action code Failure code Abnormal CAN communication (retarder controller): Communica-
tion disabled
Trouble
E03 DB1RKR (Between retarder controller – transmission controller)
Contents of
• Updating of received data from retarder controller has stopped.
trouble
• AISS is locked in LOW. (until starting switch is turned OFF.)
Action of
• Keep the information at the time when abnormality occurred.
controller
Problem that
• The information and special functions which are retrieved from retarder controller do not work or
appears on
display.
machine
Related
information

1 Between CAN2 (male) (A) – (B) (Engine Resis-
resistance 120 ± 12 z
side) tance
Between CAN2 (male) (A) – (B) (Inner cab) Resis- 120 ± 12 z

tance
(8) – BRC2 (female) (32), (22) tance
(8) – ATC2 (female) (32), (22) tance
Disconnection in wiring Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
harness (8) – J2P (female) (46), (47) tance
Possible causes 2
(Disconnection or defective Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
and standard
contact) (8) – DL (male) (3), (10) tance
value in normal
state Wiring harness between DPC4 (female) (3), Resis- Max. 1 z
(8) – CAN2 (female) (A), (B) (Engine) tance
Max. 1 z
(8) – CAN2 (female) (A), (B) (Cab) tance
Max. 1 z
Wiring harness between J2P (female) (46), Resis-
tance
(female) (A), (B)
Short circuit of harness
3 Between ground and wiring harness between Resis-
(Contact with ground circuit) Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
22 HD465-7R, HD605-7R

Between ground and wiring harness between Resis-
Min. 1 Mz
Short circuit of harness Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
3 (Contact with ground circuit) (8) – CAN1 (female) (A), (B) tance
and standard
value in normal Between ground and wiring harness between Resis-
J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
state tance
CAN2 (female) (A)
Defective engine controller If engine cannot be started, engine controller power supply may be
4
power supply defective. Carry out troubleshooting for "Failure code CA111".
transmission controller or controller, transmission controller and retarder controller, VHMS,
5
troller
HD465-7R, HD605-7R 23
Failure code [DB1RMA] Disagreement of option setting (Retarder

controller) 1
Action code Failure code Disagreement of option setting (Retarder controller)
Trouble
E03 DB1RMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in retarder controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.

Possible causes Option may be set wrongly in machine monitor. When machine
Wrong option setting in
and standard 1 monitor or retarder controller is replaced, set it correctly according
machine monitor
value in normal to Testing and adjusting.
state If cause 1 is not detected, machine monitor may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [DB2RKR] (CAN communication (engine controller):

Communication disabled) 1
Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 DB2RKR (Transmission controller system)
Contents of
trouble • Updating of received data from engine controller has stopped.
• keep the current gear speed.

Action of • Set the gearshift lever in the "N" position to keep the transmission in neutral.
controller • Keep the information at the time when abnormality occurred.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.
Related
information

2) Connect T-adapter to connectors CAN1 (male) and CAN2
(male).
1 Between CAN2 (male) (A) – (B) (Engine Resis- 120 ± 12
resistance
side) tance z
Resis- 120 ± 12
Between CAN2 (male) (A) – (B) (Inner cab)
tance z
Max. 1 z
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Max. 1 z
(8) – ATC2 (female) (32), (22) tance
Possible causes
harness Wiring harness between DPC4 (female) (3), Resis-
and standard 2 Max. 1 z
(Disconnection or defective (8) – J2P (female) (46), (47) tance
value in normal
contact)
state Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
(8) – DL (male) (3), (10) tance
Max. 1 z
Max. 1 z
Wiring harness between J2P (female) (46),
Resis-
tance
(female) (A), (B)
Short circuit of harness Min. 1 Mz
3 DPC4 (female) (3) – CAN2 (female) (A) tance
Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
26 HD465-7R, HD605-7R

Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Short circuit of harness Wiring harness between DPC4 (female) (3), Resis-
3 Max. 1 z
(Contact with ground circuit) (8) – ABS9 (female) (9), (10) tance
Possible causes Between ground and wiring harness between
Resis-
and standard J2P (female) (46) – CAN2 (female) (A) – Min. 1 Mz
tance
value in normal CAN2 (female) (A)
state Wiring harness between J2P (female) (39) –
Resis-
BT3 (20) – (19) – starting switch (terminal Max. 1 z
tance
ACC)
Defective engine controller If engine cannot be started, engine controller power supply may be
4
power supply defective. Carry out troubleshooting for "Failure code CA111".
transmission controller or controller ,transmission controller and retarder controller, VHMS,
5
troller
HD465-7R, HD605-7R 27
28 HD465-7R, HD605-7R
Failure code [DBBRKR] (Abnormality in CAN communication (VHMS)) 1

Action code Failure code Abnormality in CAN communication (VHMS)
Trouble
E03 DBBRKR (Machine monitor system)
Contents of • Machine monitor cannot obtain information from VHMS controller through CAN communication cir-
trouble cuit.
Action of
machine monitor
Problem that
appears on
machine • Information from VHMS controller is not displayed.
Related
information

and standard
state
HD465-7R, HD605-7R 29
Failure code [DBC2KK] (ABS controller solenoid power source: Power

source system trouble) 1
Action code Failure code ABS controller solenoid power source: Power source system trou-
Trouble ble
E03 DBC2KK (ABS controller system)
Contents of • While controller direct power source voltage is normal, solenoid power source voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power source.
Problem that
appears on • All systems of ABS controller do not operate.
machine
Related
• If the fuse is blown, check for ground fault of line from fuse – ABS3 (female) (2), (12), (22).
information

in ABS3.
Between battery terminal M – ground Voltage 20 – 30 V
Between ABS3 (2), (12), (22) – ground Voltage 20 – 30 V
harness If voltage at fuse BT3 (10) is normal and voltage at ABS3 (2), (12),
1 (22) is abnormal, wiring harness between fuse (10) – ABS3
Possible causes contact) (female) (2), (12), (22) has disconnection.
value in normal 2) Disconnect negative (–) terminal of battery and connect T-
state adapter to ABS3 (female).
Wiring harness between ABS3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground tance
in ABS3.
2 Defective retarder controller 3) Connect negative (–) terminal of battery.
Between ABS3 (2), (12), (22) – ground Voltage 20 – 30 V
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31

Power source voltage too low) 1
Action code Failure code ABS controller battery direct power source: Power source voltage
Trouble too low
E03 DBC3KK (ABS controller system)
Contents of
• Controller source voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • ABS does not operate.
machine
Related • When the fuse is blown, check the short circuit of line from fuse – ABS3 (female) (1), (11), (2), (12),
information (22).

a Check battery voltage and electrolyte specific gravity.
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
2) Disconnect battery (–) terminal and insert T-adapter in ABS3
(female).
Wiring harness between ABS3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground tance
Possible causes
Disconnection in wiring har- 2) Disconnect battery (–) terminal and insert T-adapter in ABS3
and standard
ness (female).
value in normal
2 (Disconnection in wiring or 3) Connect battery (–) terminal.
state
defective contact in connec- Between battery relay terminal B – ground Voltage 20 – 30 V
tor) Between ABS3 (1), (11) – ground Voltage 20 – 30 V
2) Disconnect battery (–) terminal and connect T-adapter to ABS3
(female).
If there is voltage between battery relay terminal B and ground but
not between ABS3 (1), (11) and ground, wiring harness or fuse is
broken.
Defective transmission con- and carry out troubleshooting.
3
troller
Between ABS3 (1), (11) – ground Voltage 20 – 30 V
32 HD465-7R, HD605-7R
HD465-7R, HD605-7R 33
Failure code [DBC9KQ] Disagreement of model selection (ABS

controller) 1
Action code Failure code Disagreement of model selection (ABS controller)
Trouble
E03 DBC9KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in ABS controller.
Action of • Turns all outputs OFF.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• ABS does not operate.
appears on
• All ABS output is turned OFF.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBC9KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
Installation of wrong ABS Wrong ABS controller may be installed. Check part No. of installed
2
controller ABS controller and install normal ABS controller.
Failure code [DBCRKR] (Abnormality in CAN communication (ABS)) 1

Action code Failure code Abnormality in CAN communication (ABS)
Trouble
E03 DBCRKR (Transmission controller system)
Contents of
• Machine monitor cannot obtain information from ABS controller through CAN communication circuit.
trouble
Action of
machine monitor
Problem that
appears on
• Information from ABS controller is not displayed.
machine
Related
information

and standard
state
34 HD465-7R, HD605-7R
Failure code [DBCRMA] Disagreement of option setting (ABS control-

ler) 1
Action code Failure code Disagreement of option setting (ABS controller)
Trouble
E03 DBCRMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in ABS controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
Problem that
appears on • Non in particular.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBCRMA] is not displayed.
Possible causes
Wrong option setting in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
If cause 1 is not detected, machine monitor may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
HD465-7R, HD605-7R 35

Out of input signal range) 1
Action code Failure code Trouble in travel speed setting switch system: Out of input signal
range
Trouble
E03 DDD7KX (When ARSC is set and ARSC system switch is ON)
(Retarder controller system)
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 • This failure does not have a serious effect on the machine.
machine
Related
information • None in particular.

2) Replace the travel speed set switch (ARSC SET switch).
Defective travel speed set
1 Replace the travel Failure is not
switch (ARSC SET switch) Switch is normal
speed set switch repaired.
(ARSC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Defective register (250 z) 3) Connect T-adapter.
Resis-
Between RE3 (female) (1) – (2) 250 ± 25 z
tance
3 Defective resistor (1,020 z) 3) Connect T-adapter.
Resis- 1,020 ±
Between RE4 (female) (1) – (2)
tance 102 z
2) Disconnect connectors BRC1, ARC, RE3, and RE4.
Possible causes Disconnection in wiring har- Max. 1 z
(22) – RE3 (male) (1) tance
and standard ness
value in normal 4 Wiring harness between BRC1 (female) Resis-
state (13) – RE3 (male) (2) – ARC (female) (1) tance
contact)
Wiring harness between RE4 (male) (1) – Resis-
Max. 1 z
ARC (female) (3) tance
Wiring harness between RE4 (male) (2) – Resis-
Max. 1 z
ARC (female) (2) tance
Between BRC1 (22) – (21) Voltage Approx. 5 V
2) Disconnect connectors BRC1.
When set switch is Resis- 1,020 ±
ON tance 102 z
When set switch is Resis-
68 ± 6.8 z
Between BRC1 TOUCH UP tance
(female) (13) – (21) When set switch is Resis- 198 ±
TOUCH DOWN tance 19.8 z
When set switch is Resis- 418 ±
CANCEL tance 41.8 z
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [DDD8KA] (ARSC system switch system: Disconnection)

(If equipped) 1
Action code Failure code ARSC system switch system: Disconnection
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KA (Retarder controller system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
ness 3) Connect T-adapter.
1
contact) Wiring harness between DPC2B (female) Resis-
Max. 1 z
(1) – ARSC (female) (3) tance
2) Replace the ARSC system switch with normal one.
Defective ARSC system
2 System switch is nor-
Possible causes switch When the ARSC system switch No
mal
and standard is replaced with normal one, is
value in normal failure repaired? System switch is
Yes
state defective
2) Disconnect connector DPC2B.
Turn the ARSC sys-
tem switch ON Voltage 20 – 30 V
Between DPC2B (1) (Press it up).
– ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39
Failure code [DDD8KB] (ARSC system switch system: Short circuit)

(If equipped) 1
Action code Failure code ARSC system switch system: Short circuit
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KB (Retarder controller system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

2) Disconnect connectors ARSC and DPC2B.
Hot short in wiring harness 4) Turn the starting switch ON.
1
(Contact with 24V circuit) Wiring harness between DPC2B (female)
Voltage Max. 1 V
(1) – ARSC (female) (3)
Wiring harness between DPC2B (female)
Voltage Max. 1 V
(7) – ARSC (female) (2)
2) Replace the ARSC system switch with normal one.
Possible causes 3) Turn the starting switch ON.
and standard ARSC system switch defec-
2 System switch is nor-
value in normal tive When the ARSC system switch No
mal
state is replaced with normal one, is
failure repaired? System switch is
Yes
defective
Turn the ARSC sys-
3 Machine monitor defective
– ground Turn the ARSC sys-
(Press it down).
40 HD465-7R, HD605-7R
HD465-7R, HD605-7R 41
Failure code [DDD9KA] (ABS system switch system: Disconnection) 1

Action code Failure code ABS system switch system: Disconnection
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KA (ABS controller system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
information

2) Disconnect connectors ABS and DPC2B.
Disconnection in wiring har- 3) Connect T-adapter.
ness
1 Wiring harness between DPC2B (female) Resis-
(2) – ABS (female) (3) tance
contact)
Wiring harness between DPC2B (female) Resis-
Max. 1 z
(8) – ABS (female) (2) tance
2) Replace the ABS system switch with normal one.
Possible causes
and standard 2 Defective ABS system switch System switch is nor-
When the ABS system switch is No
value in normal mal
replaced with normal one, is fail-
state ure repaired? System switch is
Yes
defective
Turn the ABS sys-
– ground Turn the ABS sys-
(Press it down).
42 HD465-7R, HD605-7R
HD465-7R, HD605-7R 43
Failure code [DDD9KB] (ABS system switch system: Short circuit) 1

Action code Failure code ABS system switch system: Short circuit
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KB (Machine moniter system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
machine moniter
Problem that
machine
Related
information

2) Disconnect connectors ABS and DPC2B.
Hot short in wiring harness Between ground and wiring harness
1
(Contact with 24V circuit) between DPC2B (female) (2) – ABS Voltage Max. 1 V
(female) (3)
Between ground and wiring harness
between DPC2B (female) (8) – ABS Voltage Max. 1 V
(female) (2)
Possible causes 2) Replace the ABS system switch with normal one.
and standard 3) Turn the starting switch ON.
value in normal 2 Defective ABS system switch System switch is nor-
state When the ABS system switch is No
mal
replaced with normal one, is fail-
ure repaired? System switch is
Yes
defective
Turn the ABS sys-
– ground Turn the ABS sys-
(Press it down).
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45
Failure code [DDDAKA] (ASR system switch: Disconnection) 1

Action code Failure code ASR system switch: Disconnection
Trouble
E01 DDDAKA (Machine monitor system)
Contents of
• The ON input of the ASR system switch is OFF and the OFF input of the system switch is OFF.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected seriously.
appears on
machine • ASR control cannot be continued.
Related
information

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring har- Wiring harness between DPC2B (female) Resis-
ness Max. 1 z
(3) – ASR (female) (3) tance
defective contact in connec- 1) Turn starting switch OFF.
tor) 2) Disconnect connectors ASR and DPC2B.
Wiring harness between DPC2B (female) Resis-
Max. 1 z
(9) – ASR (female) (2) tance
2) Replace ASR system switch with normal switch.
Possible causes 3) Turn starting switch ON.
Defective ASR system
and standard 2 System switch is nor-
switch When ASR system switch is No
value in normal mal
state replaced with normal switch,
does condition become normal? System switch is
Yes
abnormal
ASR system switch
Voltage 20 – 30 V
Between DPC2B (3) "ON"
3 Defective machine monitor – ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
– ground ASR system switch
Voltage 20 – 30 V
"OFF"
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47
Failure code [DDDAKB] (ASR system switch: Short circuit) 1

Action code Failure code ASR system switch system: Short circuit
Trouble
E01 DDDAKB (Machine monitor system)
Contents of
• ASR system switch ON input is turned ON and system switch OFF input is turned ON.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected particularly.
appears on
Related
information

2) Disconnect connectors ASR and DPC2B.
Hot short in wiring harness Between ground and wiring harness
1
(Contact with 24V circuit) between DPC2B (female) (3) – ASR Voltage Max. 1 V
(female) (3)
between DPC2B (female) (9) – ASR Voltage Max. 1 V
(female) (2)
2) Replace ASR system switch with normal switch.
Possible causes Defective ASR system
and standard 2 System switch is nor-
switch When ASR system switch is No
value in normal mal
replaced with normal switch, is
state System switch is
condition normal? Yes
defective
ASR system switch
Voltage 20 – 30 V
3 Defective machine monitor – ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
– ground ASR system switch
Voltage 20 – 30 V
"OFF"
48 HD465-7R, HD605-7R
HD465-7R, HD605-7R 49
Failure code [DDP6L4] (Service brake pressure switch trouble (Rear)) 1

Action code Failure code Service brake pressure switch trouble (Rear)
Trouble
E03 DDP6L4 (Retarder controller system)
Contents of
• When brake pedal is pressed, signal is not sent from service brake pressure switch.
trouble
Action of
controller
Problem that
appears on • When brake pedal is pressed, brake lamp (rear center lamp) does not light up.
machine
Related
information

1) Remove relay cover.
Defective stop lamp relay 2) Turn starting switch ON (Do not start engine).
1 3) Turn foot brake ON and OFF to check relay.
(R08)
R08 Turning ON/OFF sound is heard.
a Turn starting switch OFF and disconnect D09, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
Forward direction:
Between D09 (male) There is continuity
Continuity
(1) (-) – (2) (+) Backward direction:
There is not continuity
2 Defective diode
a Turn starting switch OFF and disconnect D10, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
Forward direction:
Possible causes Between D10 (male) There is continuity
Continuity
and standard (1) (-) – (2) (+) Backward direction:
value in normal There is not continuity
state a Connect wires to T-adapter for DT-T-3.
2) Disconnect S01 and connect T-adapter.
Defective service brake 3) Turn starting switch ON.
3
switch When brake pressed:
Between S01 (male) There is continuity
Continuity
(A) – (B) When brake is released:
There is not continuity
a Turn starting switch OFF and disconnect BRC1, S01 and
D10,then carry out troubleshooting without turning starting
switch ON.
Disconnection in wiring har- Between S01 (female) (A) – D10 (female) Resis-
ness (Disconnection in wiring (1) Max. 1 z
4 tance
or defective contact in con-
nector) Between BRC1 (female) (17) – D10 Resis-
Max. 1 z
(female) (2) tance
Resis-
Between S01 (female) (B) – ground Max. 1 z
tance
50 HD465-7R, HD605-7R

a Turn starting switch OFF and disconnect BRC1, S01, D09 and
D10, then carry out troubleshooting without turning starting
Grounding fault in wiring har- switch ON.
5 ness (Contact with ground Resis-
Between D10 (female) (1) – ground Min. 1 Mz
Possible causes circuit) tance
and standard Resis-
value in normal Between D10 (female) (2) – ground Min. 1 Mz
tance
state
Trouble in hydraulic system
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
normal)
7 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
HD465-7R, HD605-7R 51
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) 1

Action code Failure code Hi clutch fill switch: Disconnection
(Command is Holding pressure, fill switch is OFF, and slip is not
Trouble
E03 DDTHKA sensed)
Contents of • When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the
trouble fill switch is not turned ON.
Action of • The controller keeps the current gear speed.
controller • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
• 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.
Related
• This failure can be checked in the monitoring function (Code: 38919).
information

1 Defective Hi clutch fill switch When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN20.
value in normal ness 3) Connect T-adapter.
2
state (Disconnection or defective
contact) Wiring harness between ATC3 (female) (30) Resis-
Max. 1 z
Defective transmission con-
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
52 HD465-7R, HD605-7R
HD465-7R, HD605-7R 53
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection) 1

Action code Failure code Lo clutch fill switch: Disconnection
Trouble
E03 DDTJKA sensed)
Contents of • When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 Defective Lo clutch fill switch When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
54 HD465-7R, HD605-7R
HD465-7R, HD605-7R 55
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) 1

Action code Failure code 1st clutch fill switch: Disconnection
Trouble
E03 DDTKKA sensed)
Contents of • When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the
controller • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
Related
information

1 Defective 1st clutch fill switch When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
56 HD465-7R, HD605-7R
HD465-7R, HD605-7R 57
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) 1

Action code Failure code 2nd clutch fill switch: Disconnection (KA)
Trouble
E03 DDTLKA sensed)
Contents of • When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

Defective 2nd clutch fill
1 When dis- Resis-
switch Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
58 HD465-7R, HD605-7R
HD465-7R, HD605-7R 59
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) 1

Action code Failure code 3rd clutch fill switch: Disconnection
Trouble
E03 DDTMKA sensed)
Contents of • When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

Defective 3rd clutch fill
1 When dis- Resis-
switch Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
60 HD465-7R, HD605-7R
HD465-7R, HD605-7R 61
Failure code [DDTNKA] (R clutch fill switch: Disconnection) 1

Action code Failure code R clutch fill switch: Disconnection
Trouble
E03 DDTNKA sensed)
Contents of • When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 Defective R clutch fill switch When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
62 HD465-7R, HD605-7R
HD465-7R, HD605-7R 63
Failure code [DDTPKA] (4th clutch fill switch: Disconnection) 1

Action code Failure code 4th clutch fill switch : Disconnection
Trouble
E03 DDTPKA sensed)
Contents of • When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 Defective 4th clutch fill switch When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
64 HD465-7R, HD605-7R
HD465-7R, HD605-7R 65
Failure code [DF10KA] (Gear shift lever: Disconnection) 1

Action code Failure code Gear shift lever: Disconnection
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• Gear shift lever signal is not input at all.
trouble
Action of
• Controls according to previous gear shift lever information before abnormality occurs.
controller
Problem that • Gear speed is still in neutral and cannot start vehicle.
appears on • Cannot shift between forward and reverse positions.
machine • All gear shift lever position lamps go out.
Related infor-
mation

• Gear shift lever is being pushed even though it is not operated.
1 Operational error • Gear shift lever has been stopped at the midway point between
each of the gear positions.
2) Connect T-adapter to connector SF1 (male).
Resis-
Harness between BT3 (14) – SF1 (male) (1) Max. 1 z
tance
Max. 1 z
– SF1 (male) (3) tance
Max. 1 z
Max. 1 z
Disconnection in wiring Wiring harness between ATC2 (female) (15) Resis-
Max. 1 z
harness – SF1 (male) (6) tance
2
(Disconnection or defective Wiring harness between ATC2 (female) (5) Resis-
contact of connectors) Max. 1 z
Max. 1 z
Possible causes – SF1 (male) (8) tance
and standard Wiring harness between ATC2 (female) (26) Resis-
state
Max. 1 z
Max. 1 z
Max. 1 z
(31), (32), (33) – SF1 (male) (2) tance
2) Connect T-adapter to connectors ATC1 (female), ATC2 (female),
and SF1 (male).
Min. 1 Mz
ATC2 (female) (35) – SF1 (male) (3) tance
Defective harness grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground circuit) ATC2 (female) (25) – SF1 (male) (5) tance
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
66 HD465-7R, HD605-7R

Min. 1 Mz
Min. 1 Mz
Defective harness grounding ATC2 (female) (26) – SF1 (male) (9) tance
3
(Contact with ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
Min. 1 Mz
2) Insert T-adapter in connector SF1.
In shift range "R" Voltage 20 – 30 V
Between SF1 (3) –
ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "N" Voltage 20 – 30 V
Between SF1 (4) –
Voltage Max. 1 V
than "N"
In shift range "D" Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than "D"
In shift range "6" Voltage 20 – 30 V
Between SF1 (6) –
Voltage Max. 1 V
than "6"
Possible causes 4 Defective gear shift lever
and standard Between SF1 (7) –
value in normal Voltage Max. 1 V
than "5"
state
Between SF1 (8) –
Voltage Max. 1 V
than "4"
Between SF1 (9) –
Voltage Max. 1 V
than "3"
Between SF1 (10) –
Voltage Max. 1 V
than "2"
In shift range "L" Voltage 20 – 30 V
Voltage Max. 1 V
than "L"
2) Insert T-adapter in connectors ATC1 and ATC2.
Between ATC2 (35) –
Voltage Max. 1 V
Defective transmission than "R"
5
controller In shift range "D" Voltage 20 – 30 V
Voltage Max. 1 V
than “D“
Voltage Max. 1 V
than "N"
HD465-7R, HD605-7R 67

Voltage Max. 1 V
than "6"
Voltage Max. 1 V
than "5"
Possible causes Between ATC2 (36) –
and standard Voltage Max. 1 V
Defective transmission than "4"
value in normal 5
state controller In shift range "3" Voltage 20 – 30 V
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "L"
68 HD465-7R, HD605-7R
Failure code [DF10KB] (Gear shift lever: Short circuit) 1

Action code Failure code Gear shift lever: Short circuit
Trouble (Input of multiple lever signach)
E03 DF10KB (Transmission controller system)
Contents of
• Gear shift lever signals have been inputted at the same time from 2 or more systems.
trouble
• Controls according to high priority signal.
(1): N > D > 6> 5 > 4 > 3 > 2 > L
Action of
(2): N > R
controller
• Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the
same time.
• There are cases where the gear speed is shifted to a higher gear speed than that which has been
Problem that
set by the gear shift lever.
appears on
• Gear speed is still in neutral and cannot start vehicle.
machine
• Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
information

2) Connect T-adapter to connectors ATC1 (female), ATC2
(female), and SF1 (male).
When not
Between ground and wiring harness between
Voltage at R, Max.
ATC2 (female) (35) – SF1 (male) (3)
1V
When not
Voltage at D, Max.
1V
When not
Voltage at N, Max.
1V
When not
Defective hot short in wiring Voltage at 6, Max.
1 harness 1V
Possible causes (Contact with 24 V circuit) When not
and standard Voltage at 5, Max.
value in normal 1V
state When not
Voltage at 4, Max.
1V
When not
Voltage at 3, Max.
1V
When not
Voltage at 2, Max.
1V
When not
Voltage at L, Max.
1V
2) Insert T-adapter in connector SF1 (male).
2 Defective gear shift lever
Between SF1 (3) –
Voltage Max. 1 V
than "R"
HD465-7R, HD605-7R 69

Between SF1 (4) –
Voltage Max. 1 V
than "N"
In shift range"D" Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than "D"
Between SF1 (6) –
Voltage Max. 1 V
than "6"
Between SF1 (7) –
Voltage Max. 1 V
than "5"
2 Defective gear shift lever
Between SF1 (8) –
Voltage Max. 1 V
than "4"
Between SF1 (9) –
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "L"
Possible causes a Turn the starting switch OFF.
and standard
value in normal In shift range "R" Voltage 20 – 30 V
state ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "D" Voltage 20 – 30 V
Voltage Max. 1 V
than "D"
In shift range"N" Voltage 20 – 30 V
Voltage Max. 1 V
than “N“
Voltage Max. 1 V
than "6"
Defective transmission In shift range "5" Voltage 20 – 30 V
3 Between ATC2 (5) –
controller In shift range other
ground Voltage Max. 1 V
than "5"
Voltage Max. 1 V
than "4"
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "L"
70 HD465-7R, HD605-7R
HD465-7R, HD605-7R 71
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of

input signal range) 1
Action code Failure code Transmission oil temperature sensor: Out of input signal range
Trouble
E03 DGF1KX (Transmission controller system)
• The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above
Contents of 150°C) or only transmission oil temperature is low (transmission oil temperature sensor signal cir-
trouble cuit voltage is above 4.56 V (below 15 °C) and torque converter and brake oil temperature sensor
voltage is below 3.7 V (above 55 °C).
Action of
• The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
controller
Problem that
appears on • Gear shift shocks become large.
machine
• This failure can be checked in the monitoring function (Code: 32500 (°C), 32501 (V)).
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".

Defective transmission oil
1 Between Oil temperature: 25°C Resis-
temperature sensor 37 – 50 kz
CN23 tance
(male) (1) Resis-
– (2) Oil temperature: 100°C 3.5 – 4.0 kz
tance
ness
contact)
Max. 1 z
value in normal Grounding fault in wiring har- 3) Connect T-adapter.
3
state ness (Contact with ground)
Between ground and wiring harness ATC1 Resis-
Min. 1 Mz
(female) (3) – CN23 (female) (1) tance
Hot short in wiring harness 3) Connect T-adapter.
(Contact with 24V)
Between ground and wiring harness ATC1
Voltage Max. 5 V
(female) (3) – CN23 (female) (1)
5
troller Between Oil temperature: 25°C Resis-
37 – 50 kz
ATC1 tance
(female) Resis-
(3) – (21) Oil temperature: 100°C tance
3.5 – 4.0 kz
72 HD465-7R, HD605-7R
HD465-7R, HD605-7R 73
Failure code [DGR2KZ] (Retarder oil temperature sensor system trouble

: Ground fault (Rear wheel)) 1
Action code Failure code Retarder oil temperature sensor system trouble : Ground fault
Trouble (Rear wheel)
E01 DGR2KZ (Retarder controller system)
Contents of
• Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
appears on • Oil temperature gauge does not work because of failure mode of sensor.
machine
Related • Input signal from oil temperature sensor can be checked with monitoring function (codes: 30211
information (°C) and 30212 (V)).

a Prepare with starting switch OFF, disconnect connector RTR
and troubleshooting with starting switch still OFF.
Retarder oil tempera-
M04 (male) Resistance (kz)
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) – (2) 80 6.556
90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
BRC1 (female) Resistance (kz)
Disconnection in wiring ture (°C)
harness 25 42.7
2
Possible causes (Disconnection or defective
30 35.13
and standard contact)
value in normal Between (3) – (21) 80 6.556
state 90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
BRC1 (female) Resistance (kz)
Short circuit of harness ture (°C)
(Contact with ground circuit 25 42.7
3
or contact between har-
30 35.13
nesses)
Between (3) – (21) 80 6.556
90 4.925
100 3.75
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30203).
74 HD465-7R, HD605-7R
HD465-7R, HD605-7R 75
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal

out of range) 1
Action code Failure code Steering oil temperature sensor: Input signal out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Signal circuit voltage of steering oil temperature sensor has reached 0.97 V (more than 150 °C) or
only steering oil temperature is low (signal circuit voltage of steering oil temperature sensor is above
Contents of
4.56 V (less than 15 °C)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55 °C )
and normal.
Action of
controller
Problem that
appears on • Steering oil temperature gauge does not indicate properly.
machine
• Input signal from oil temperature sensor can be checked with monitoring function.
Related 1) Steering oil temperature sensor (codes: 32701 (°C) and 32702) (V))
information 2) Torque converter oil temperature sensor (codes: 30100 (°C) and 30101 (V))
3) Retarder oil temperature sensor (codes: 30211 (°C) and 30212 (V))

2) Connect T-adapter to connector STR (male).
Defective steering oil Between Oil temperature: Resis-
1 37 – 50 kz
temperature sensor STR 25 °C tance
(male) (1) Oil temperature: Resis-
– (2) 3.5 – 4.0 kz
100 °C tance
2) Connect T-adapter to connectors ATC1 (female) and STR
Disconnection in wiring (female).
harness
– STR (female) (1) tance
contact)
Max. 1 z
– STR (female) (2) tance

and standard 2) Disconnect connectors ATC1 and STR.
value in normal Defective harness grounding 3) Connect T-adapter to connector ATC1 (female).
3
Resis-
between ATC1 (female) (20) – STR (female) Min. 1 Mz
tance
(1)
2) Disconnect connectors ATC1 and STR.
Hot short in wiring harness 4) Turn starting switch ON.
4
(Contact with 24 V circuit)
between ATC1 (female) (21) – STR (female) Voltage Max. 5V
(2)
Defective transmission Between Oil temperature: Resis-
5 37 – 50 kz
controller ATC1 25 °C tance
(female) Oil temperature: Resis-
(20) – (21) 3.5 – 4.0 kz
100 °C tance
76 HD465-7R, HD605-7R
HD465-7R, HD605-7R 77
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Transmission controller system)
• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V
Contents of (above 150°C) or when transmission valve oil temperature signal voltage is below 0.37 V (above
trouble 5C°) and there is no abnormality, torque converter oil temperature sensor signal circuit voltage is
above 4.56 V (below 15°C).
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge does not indicate normally.
machine
Related
• This failure can be checked in the monitoring function (Code: 30100 (°C), 30101 (V)).
information

Defective torque converter
1 Between Oil temperature: 25°C Resis-
oil temperature sensor 37 – 50 kz
CN22 tance
(male) (1) Resis-
– (2) Oil temperature: 100°C 3.5 – 4.0 kz
tance
ness
contact)
Max. 1 z
and standard Grounding fault in wiring har- 2) Disconnect connectors ATC1 and CN22.
value in normal 3 ness 3) Connect T-adapter.
state (Contact with ground circuit) Between ground and wiring harness ATC1 Resis-
Min. 1 Mz
(female) (9) – CN22 (female) (1) tance
Defective hot short in wiring 3) Insert T-adapter.
4 harness 4) Turn the starting switch ON.
(Contact with 24V circuit)
Between ground and wiring harness ATC1
Voltage Max. 1 V
(female) (21) – CN22 (female) (2)
5
troller Between Oil temperature: 25°C Resis-
37 – 50 kz
AT1 tance
(female) Resis-
(9) – (21) Oil temperature: 100°C tance
3.5 – 4.0 kz
78 HD465-7R, HD605-7R
HD465-7R, HD605-7R 79

© 2007 KOMATSU
All Rights Reserved
80 HD465-7R, HD605-7R
SEN02538-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [DHP6KA] (Suspension pressure sensor system:
Disconnection right rear).......................................................................................................................... 3
Out of input signal range (Right rear)) ..................................................................................................... 4
Failure code [DHP6KY] (Suspension pressure sensor system: Short circuit (Right rear)) ............................. 6
Disconnection or ground fault (Right rear)).............................................................................................. 6
Failure code [DHP7KA] (Suspension pressure sensor system: Disconnection (Left rear)) ............................ 7
Out of input signal range) (Left rear)........................................................................................................ 8
Failure code [DHP7KY] (Suspension pressure sensor system:
Short circuit (Left rear)) .......................................................................................................................... 10
Disconnection or ground fault (Left rear)) ...............................................................................................11
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) .......................... 12
HD465-7R, HD605-7R 1

Disagreement of run and stop condition with signal) ............................................................................. 14
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)........................ 16
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) ........................ 18
Failure code [DJF1KA] (Fuel level sensor: Disconnection)........................................................................... 20
Failure code [DK30KX] (Steering angle potentiometer: Trouble (Disconnection)) ........................................ 21
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with swich signal).......................................................................... 22
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)........................... 26
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) .................. 28
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) ................................................ 30
Failure code [DKD0L6] (Failure in steering speed sensor) ........................................................................... 32
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range)....................................................... 34
Failure code [DKH1KX] (Pitch angle sensor: Abnormality (Disconnection or short circuit)) ......................... 36
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ........................................ 38
Disagreement of revolution speed signal).............................................................................................. 40
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) ............................ 42
Disagreement of revolution speed signal).............................................................................................. 44
2 HD465-7R, HD605-7R

Disconnection right rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection rear right
Trouble
E01 DHP6KA (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
appears on • There is no great influence of machine.
machine
• The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32816 (MPa), 32817 (V)).
information
• This failure occurs only when the built-in PLM function is installed.

and standard
value in normal Carry out troubleshooting for failure code [DH6KX].
state
HD465-7R, HD605-7R 3
Failure code [DHP6KX] (Failure in suspension pressure sensor system

trouble: Out of input signal range (Right rear)) 1
Action code Failure code Failure in suspension pressure sensor system trouble: Out of input
Trouble signal range (Right rear)
E03 DHP6KX (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
machine
Related • The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
information tion (Code: 32816 (MPa), 32817 (V)).

2) Disconnect connectors BRC1, SURR, and PM6.
Disconnection in wiring Wiring harness between BRC1 (female) (7) Resis-
harness Max. 1 z
1 – SURR (female) (C) tance
contact) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(21) – SURR (female) (A) tance
Wiring harness between PM6 (female) (2) – Resis-
Max. 1 z
SURR (female) (B) tance
2) Disconnect connectors BRC1, SURR, PM6.
3) Connect T-adapter to PM6 (female).
Grounding fault in wiring
Wiring harness between BRC1 (female) (7) Resis-
2 harness Min. 1 Mz
– SURR (female) (C) tance
Resis-
Possible causes between BRC1 (female) (21) – SURR Min. 1 Mz
tance
and standard (female) (A)
state 2) Disconnect connectors PM6, BRC1, and SURR.
Defective hot short in wiring 3) Connect T-adapter to BRC1 (female).
3 harness 4) Turn starting switch ON.
(Contact with 24V circuit) Between ground and wiring harness
between BRC1 (female) (7) – SURR Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURR.
Defective suspension 3) Insert T-adapter.
4
pressure sensor (Right rear) 4) Turn starting switch ON.
Between SURR (B) – (A) Voltage 18 ± 3 V
Between SURR (C) – (A) Voltage 1.0 – 4.6 V
Defective retarder 3) Insert T-adapter.
5
controller 4) Turn starting switch ON.
Between BRC1 (7) – (21) Voltage 1.0 – 4.6 V
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [DHP6KY] (Suspension pressure sensor system: Short

circuit (Right rear)) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Right rear)
Trouble
E01 DHP6KY (VHMS controller system) (Display: PLM)
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor (right rear).
trouble
Action of
• Stops auto-suspension function.
controller
Problem that
appears on • Auto-suspension function does not operate.
machine
Related
• Suspension pressure can be checked with monitoring function (Code: 32816 (MPa), 32817 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [DHP6KX].
state

Disconnection or ground fault (Right rear)) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Right rear)
E01 DHP6KZ (VHMS controller system) (Display: PLM)
Contents of
• Signal is not sent from suspension pressure sensor (right rear) or it is grounded.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
6 HD465-7R, HD605-7R

Disconnection (Left rear)) 1
Action code Failure code Suspension pressure sensor system: Disconnection (Left rear)
Trouble
E01 DHP7KA (Retarder controller system)
Contents of
• The voltage of the signal circuit of the suspension pressure sensor (Left rear) is below 0.3 V.
trouble
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

and standard
state
HD465-7R, HD605-7R 7
Failure code [DHP7KX] (Failure in suspension pressure sensor system

trouble: Out of input signal range) (Left rear) 1
Action code Failure code Failure in suspension pressure sensor system trouble (Left rear):
Out of input signal range
Trouble
E03 DHP7KX (When ARSC is not set or ARSC system switch is "ON")
Contents of • The voltage of the signal circuit of the suspension pressure sensor (left) is below1.0 V or above 4.6
trouble V.
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

2) Disconnect connectors BRC1, SURL, and PM6.
Disconnection in wiring Wiring harness between PM6 (female) (6) – Resis-
harness Max. 1 z
1 SURL (female) (C) tance
contact) Wiring harness between PM6 (female) (3) – Resis-
Max. 1 z
SURL (female) (A) tance
Wiring harness between PM6 (female) (2) – Resis-
Max. 1 z
SURL (female) (B) tance
2) Disconnect connectors BRC1, SURL, and PM6.
Grounding fault in wiring Between ground and wiring harness
Resis-
2 harness between BRC1 (female) (1) – SURL Min. 1 Mz
tance
(Contact with ground circuit) (female) (C)
Possible causes Resis-
between PM6 (female) (2) – SURL (female) Min. 1 Mz
and standard tance
(B)
value in normal
2) Disconnect connectors BRC1, and SURL.
3
between BRC1 (female) (1) – SURL Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURL.
Defective suspension 3) Insert T-adapter.
4 4) Turn starting switch ON.
pressure sensor (Left rear)
Between SURL (B) – (A) Voltage 18 ± 3 V
Between SURL (C) – (A) Voltage 1.0 – 4.6 V
5 Defective retarder controller 3) Insert T-adapter.
8 HD465-7R, HD605-7R
HD465-7R, HD605-7R 9
Failure code [DHP7KY] (Suspension pressure sensor system: Short

circuit (Left rear)) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Left rear)
Trouble
E01 DHP7KY (VHMS controller system) (Display: PLM)
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
10 HD465-7R, HD605-7R

Disconnection or ground fault (Left rear)) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Left rear)
E01 DHP7KZ (VHMS controller system) (Display: PLM)
Contents of
• Signal is not sent from suspension pressure sensor or it is grounded (Abnormal).
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
HD465-7R, HD605-7R 11
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of

Action code Failure code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX (Transmission controller system)
Contents of • The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in
controller itself.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32600 (MPa), 32605 (V)).
information

2) Disconnect connectors ATC1, ATC3, and CN21.
Disconnection in wiring Wiring harness between ATC3(female) (8) – Resis-
harness Max. 1 z
1 CN21 (female) (B) tance
contact) Wiring harness between ATC1(female) (21) Resis-
Max. 1 z
– CN21 (female) (A) tance
Max. 1 z
– CN21 (female) (C) tance
Grounding fault in wiring Between ground and wiring harness
Resis-
2 harness between ATC3A (female) (8) – CN21 Min. 1 Mz
tance
(Contact with ground circuit) (female) (B)
Resis-
Possible causes between ATC1 (female) (1) – CN21 (female) Min. 1 Mz
tance
and standard (C)
value in normal 1) Turn the starting switch OFF.
state 2) Disconnect connectors ATC3 and CN21.
(Contact with 24V circuit) Between ground and wiring har-
ness between ATC3 (female) (8) Voltage 0.8 – 2.0 V
– CN21 (female) (B) – ground
Defective torque converter 3) Insert T-adapter.
oil pressure sensor
Between CN21 (B) – (A) Voltage 20 – 30 V
Between CN21 (C) – (A) Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3.
Defective transmission con- 3) Insert T-adapter.
troller
Between ATC1 (1) – (21) Voltage 20 – 30 V
Between ATC3 (8) – ATC1 (21) Voltage 0.8 – 2.0 V
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13

Disagreement of run and stop condition with signal) 1
Action code Failure code Torque converter oil pressure sensor: Disagreement of run and
Trouble stop condition with signal
E01 DHT5L6 (Transmission controller system)
Contents of • While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque con-
trouble verter oil pressure sensor.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure init-
controller self.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32601 (MPa), 32602 (V)).
information

Wiring harness between ATC1 (female) (1)
Voltage Max. 1.2 V
– CN21 (female) (C)
Possible causes 2) Disconnect connector CN21.
and standard 3) Insert T-adapter.
Defective torque converter
value in normal 2 4) Turn the starting switch ON.
oil pressure sensor
state
Between CN21 (B) – (A) Voltage 20 – 30 V
Between CN21 (C) – (A) Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3.
Defective transmission con- 3) Insert T-adapter.
troller
Between ATC3 (8) – ATC1 (21) Voltage 20 – 30 V
Between ATC1 (1) – (21) Voltage 0.8 – 2.0 V
14 HD465-7R, HD605-7R
HD465-7R, HD605-7R 15
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of

Action code Failure code Front accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU2KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35500 (MPa), and
Related 35504 (V)).
information • When only rear accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Connect T-adapter to connectors ATC1 (female) and ACCF
(female).
harness Max. 1 z
1 – ACCF (female) (C) tance
(Disconnection or
defective contact) Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
– ACCF (female) (A) tance
Max. 1 z
– ACCF (female) (B) tance
2) Connect T-adapter to connectors ATC1 (female) and ACCF
(female).
Defective harness grounding Resis-
2 between ATC1 (female) (13) – ACCF Min. 1 Mz
(Contact with ground circuit) tance
(female) (C)
Possible causes
and standard Between ground and wiring harness
Resis-
value in normal between ATC1 (female) (22) – ACCF Min. 1 Mz
tance
state (female) (B)
2) Connect T-adapter to connectors ACCF and ATC1
3
Voltage Max. 1 V
between ATC1 (13) – ACCF (C)
2) Connect T-adapter to connector ACCF.
Defective front accumulator 3) Carry out troubleshooting while starting switch is ON.
4
oil pressure sensor
Between ACCF (B) – (A) Voltage 4.6 – 5.4 V
Between ACCF (C) – (A) Voltage 0.3 – 4.7 V
2) Insert T-adapter in connector ATC1.
5
troller
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of

Action code Failure code Rear accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU3KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35501 (MPa), and
Related 35505 (V)).
information • When only front accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Connect T-adapter to connectors ATC1 (female) and ACCR
(female).
harness Max. 1 z
1 – ACCR (female) (C) tance
(Disconnection or
defective contact) Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
– ACCR (female) (A) tance
Max. 1 z
– ACCR (female) (B) tance
2) Connect T-adapter to connectors ATC1 (female) and ACCR
(female).
Defective harness grounding Resis-
2 between ATC1 (female) (7) – ACCR Min. 1 Mz
(female) (C)
Possible causes
and standard Between ground and wiring harness
Resis-
value in normal between ATC1 (female) (22) – ACCR Min. 1 Mz
tance
state (female) (B)
2) Connect T-adapter to connectors ATC1 and ACCR.
3
(a contact with 24V circuit)
Voltage Max. 1 V
between ATC1 (female) (7) – ACCR (C)
2) Connect T-adapter to connector ACCR.
Defective rear accumulator 3) Carry out troubleshooting while starting switch is ON.
4
oil pressure sensor
Between ACCR (B) – (A) Voltage 4.6 – 5.4 V
Between ACCR (C) – (A) Voltage 0.3 – 4.7 V
2) Insert T-adapter in connector ATC1.
5
troller
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 1

Action code Failure code Fuel level sensor: Disconnection
Trouble
E01 DJF1KA (Transmission controller system)
Contents of
trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Action of
controller • None in particular.
Problem that
appears on • The fuel level gauge does not indicate normally.
machine
Related
information z)).
• This failure can be checked in the monitoring function (Code: 04200 (V), 04201 (z

2) Disconnect connector FUEL.
1 Defective fuel level sensor Fuel level: Resis-
Max. 12 z
Between FUEL When FULL tance
(male) (1) – (2) Fuel level: Resis-
74 – 100 z
When EMPTY tance
2) Disconnect connectors ATC1and FUEL.
harness
– FUEL (female) (1) tance
Possible causes contact)
and standard Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
value in normal – FUEL (female) (2) tance
state 1) Turn the starting switch OFF.
2) Disconnect connectors ATC1and FUEL.
Defective hot short in wiring 3) Connect T-adapter.
Voltage Max. 1 V
ATC1(female) (8) – FUEL (female) (1)
4
troller Fuel level: Resis-
Max. 12 z
Between ATC1 When FULL tance
(female) (8) – (21) Fuel level: Resis-
74 – 100 z
When EMPTY tance
20 HD465-7R, HD605-7R
Failure code [DK30KX] (Steering angle potentiometer: Trouble

(Disconnection)) 1
Action code Failure code Steering angle potentiometer: Trouble (Disconnection)
Trouble
E01 DK30KX (Retarder controller system)
Contents of
trouble • There is no voltage in signal coming from steering angle potentiometer.
Action of
Problem that
appears on • Since steering angle signal is not input to retarder controller, ASR may not operate normally and
machine tires may slip consequently.
Related
information

Turn starting switch OFF and disconnect ASR1, then carry out
troubleshooting without turning starting switch ON.
ASR1 (Male: Sensor side) Resistance
Defective steering angle Between (A) – (C) 5 kz ± 20%
1
sensor
Between (A) – (B) 0 – 5 kz *1
Between (B) – (C) 0 – 5 kz *1
*1 Between (A) – (B) + between (B) – (C) = 5 kz ± 20%
a Turn starting switch OFF and disconnect ASR1, then carry out
Possible causes Between ASR1 (female) (B) – BRC1 Resis-
and standard Max. 1 z
Disconnection in wiring har- (female) (2) tance
value in normal ness (Disconnection in wiring
state 2
or defective contact in con- 1) Turn starting switch OFF and disconnect ASR1.
nector) 2) Turn starting switch ON and carry out troubleshooting.
ASR1 (Female: Wiring harness
Voltage
side)
Between (C: +) – (A: -) 5V
a Turn starting switch OFF and disconnect R14 (BCV relay), then
Grounding fault in wiring har- carry out troubleshooting without turning starting switch ON.
3 ness (Contact with ground
circuit) Resis-
Between ASR1 (female) (B) – ground Min. 1 Mz
tance
out.)
HD465-7R, HD605-7R 21
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer

signal is inconsistent with swich signal) 1
Action code Failure code Retarder lever potentiometer: Potentiometer signal is inconsistent
Trouble with swich signal
E03 DK51L5 (Retarder controller system)
Contents of • The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
trouble the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
Action of • Controls with the potentiometer signal.
controller • 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
• The retarder cannot control finely.
machine
• The retarder does not operate (The foot brake operates, however).
Related
• This failure can be checked in the monitoring function (Code: 33900 (V)).
information

2) Disconnect connectors BRC1, BRC3, RE1, and RTL.
Max. 1 z
(22) – RE1 (female) (1) tance
Wiring harness between RE1 (female) (2) – Resis-
Max. 1 z
RTL (female) (1) tance
Disconnection in wiring Wiring harness between BRC1 (female) Resis-
harness Max. 1 z
1 (21) – RTL (female) (3) tance
Max. 1 z
(14) – RTL (female) (2) tance
(24) – RTL (female) (4) tance
and standard
value in normal Wiring harness between BRC1 (female) Resis-
Max. 1 z
state (18) – RTL (female) (5) tance
Wiring harness between RTL (female) (6) – Resis-
Max. 1 z
BRC3 (female) (21), (31), (32), (33) tance
2) Disconnect connectors BRC1, RE1, and RTL.
Resis-
Grounding fault in wiring between BRC1 (female) (22) – RE1 (female) Min. 1 Mz
tance
2 harness (1)
(Contact with ground circuit) Between ground and wiring harness Resis-
Min. 1 Mz
between RE1 (female) (2) – RTL (female) (1) tance
Resis-
between BRC1 (female) (14) – RTL (female) Min. 1 Mz
tance
(2)
22 HD465-7R, HD605-7R

2) Disconnect connectors BRC1 and RTL.
Hot short in wiring between BR1 (female) (22) – RE1 (female) Voltage Max. 1 V
3 harness (1)
Voltage Max. 1 V
between RE1 (female) (2) – RTL (female) (1)
between BRC1 (female) (14) – RTL (female) Voltage Max. 1 V
(2)
4 Defective resistor (RE1) 3) Connect T-adapter.
Resis-
Between RE1 (male) (1) – (2) 250 ± 5 z
tance
2) Disconnect connector RTL
5) Check the potentiometer.
Between RTL (1) – (3) Voltage 4.1 – 4.8 V
Between RTL (2) – (3) Voltage 0.3 – 4.7 V
2) Disconnect connector RTL
Possible causes 5 Defective retarder lever 3) Connect T-adapter.
and standard 4) Check the switch.
value in normal
Resis-
state Lever at OFF position Max. 1 z
Between RTL (male) tance
(4) – (6) Resis-
Lever at ON position Min. 1 Mz
tance
Resis-
Lever at OFF position Min. 1 Mz
Between RTL (male) tance
(5) – (6) Resis-
Lever at ON position Max. 1 z
tance
2) Disconnect connectors BRC1, and BRC3.
Between BRC1 (22) – BRC3,
Voltage 4.1 – 4.8 V
(21), (31), (32), (33)
Between BRC1 (14) – BRC3,
(21), (31), (32), (33)
2) Disconnect connector RTL.
6 Defective retarder controller 3) Connect T-adapter.
4) Check the switch.
Resis-
Between BRC1 Lever at OFF position Max. 1 z
tance
(female) (24) –
ground Resis-
Lever at ON position Min. 1 Mz
tance
Resis-
Between BRC1 Lever at OFF position Min. 1 Mz
tance
(female) (18) –
ground Resis-
Lever at ON position Max. 1 z
tance
HD465-7R, HD605-7R 23
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of

Action code Failure code Failure in hoist lever potentiometer 1: Out of input signal range
Trouble (Out of input signal range of lever potentiometer 1 or 2)
Contents of • The signal voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 0.3 V or above 4.7
trouble V.
Action of
• Operates body by using normal one of 2 potentiometers.
controller
Problem that
appears on • Machine is not affected in particular.
machine
Related
information

2) Disconnect connectors BRC1, BRC3, and HSL.
Disconnection in wiring Max. 1 z
(34) – HSL (female) (4) tance
harness
1 Wiring harness between BRC1 (female) Resis-
contact)
Max. 1 z
Max. 1 z
Resis-
Possible causes between BRC3 (female) (34) – HSL (female) Min. 1 Mz
Grounding fault in wiring tance
and standard (4)
2 harness
value in normal (Contact with ground circuit) Between ground and wiring harness Resis-
state between BRC1 (female) (20) – HSL (female) Min. 1 Mz
tance
(2)
Resis-
between BRC1 (female) (19) – HSL (female) Min. 1 Mz
tance
(3)
between BRC3 (female) (34) – HSL (female) Voltage Max. 1 V
Hot short in wiring harness (4)
3
(2)
(3)
26 HD465-7R, HD605-7R

2) Disconnect connector HSL.
4 Defective hoist lever
Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Possible causes Between HSL (2) – (1) Voltage 0.3 – 4.7 V

and standard Between HSL (3) – (1) Voltage 0.3 – 4.7 V
state 2) Disconnect connectors BRC1, BRC3, and HSL.
4)Turn the starting switch ON.
5 Defective retarder controller Between BRC3 (34) – BRC1
(21)
HD465-7R, HD605-7R 27
Failure code [DK53L8] (Failure in hoist lever potentiometer 2:

Disagreement of analog signal) 1
Action code Failure code Failure in hoist lever potentiometer 2: Disagreement of analog
Trouble signal
E03 DK53L8 (Retarder controller system)
Contents of
• The total voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
trouble
Action of
• The controller recognizes the hoist lever position as "NEUTRAL".
controller
Problem that
appears on • Body does not operate.
machine
Related • This failure can be checked in the monitoring function (Code: 34305 (V)).
information • If the failure code "DK52KX" is displayed, perform troubleshooting for it.

2) Disconnect connector HSL.
Possible causes 4) Turn the starting switch ON.
and standard 1 Defective hoist leverx
value in normal Between HSL (4) – (1) Voltage 4.6 – 5.4 V
state Between HSL (2) – (1) Voltage 0.3 – 4.7 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.
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [DK54KX] (Body positioner sensor: Out of input signal

range) 1
Action code Failure code Body positioner sensor: Out of input signal range
Trouble
Contents of
• The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
trouble
Action of • The controller controls dumping according to the hoist lever signal.
controller • The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that
• The hoist lever positioner does not function.
appears on
machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the hoist lever is not at "FLOAT".
Related
information

2) Disconnect connectors BRC1, BRC3, and B07.
Disconnection in wiring Wiring harness between BRC1 (female) (8) Resis-
harness Max. 1 z
1 – B07 (female) (B) tance
Max. 1 z
(34) – B07 (female) (C) tance
Max. 1 z
(21) – B07 (female) (A) tance
2) Disconnect connectors BRC1, BRC3, and B07.
2 harness Min. 1 Mz
– B07 (female) (B) tance
Possible causes Between ground and wiring harness
and standard Resis-
between BRC3 (female) (34) – B07 (female) Min. 1 Mz
value in normal tance
(C)
state
2) Disconnect connectors BRC1, BRC3B, and B07.
Hot short in wiring
3 harness
between BRC1 (female) (8) – B07 (female) Voltage Max. 1 V
(B)
between BRC3 (female) (34) – B07 (female) Voltage Max. 1 V
(C)
2) Disconnect connector B07.
4 Defective body positioner 4) Turn the starting switch ON.
Between B07 (C) – (A) Voltage 4.6 – 5.4 V
Between B07 (B) – (A) Voltage 0.3 – 4.7 V
30 HD465-7R, HD605-7R

Possible causes 2) Disconnect connectors BRC1, BRC3, and B07.
value in normal 5 Defective retarder controller 4) Turn the starting switch ON.
state Between BRC1 (8) – (21) Voltage 4.1 – 4.8 V
Between BRC3 (34) – BRC1
(21)
HD465-7R, HD605-7R 31
Failure code [DKD0L6] (Failure in steering speed sensor) 1

Action code Failure code Failure in steering speed sensor
Trouble
E01 DKD0L6 (Retarder controller system)
Contents of • Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sen-
trouble sor and no signals are input.
Action of
controller • Fix the auto-suspension in the M mode.
Problem that
machine
Related
information • This failure can be checked in the monitoring function (Code: 35403 (rad/s)).

2) Disconnect connectors BRC1, BRC2, and SR3.
Disconnection in wiring Wiring harness between BRC2 (female) Resis-
harness Max. 1 z
1 (29) – SR3 (female) (3) tance
Max. 1 z
(37) – SR3 (female) (2) tance
Max. 1 z
(16) – SR3 (female) (1) tance
2) Disconnect connectors BRC1, BRC2, and SR3.
2 harness Between ground and wiring harness between Resis-
Min. 1 Mz
(Contact with ground circuit) BRC2 (female) (37) – SR3 (female) (2) tance
Min. 1 Mz
BRC1 (female) (16) – SR3 (female) (1) tance
Possible causes 2) Disconnect connector SR3.
value in normal 4) Turn the starting switch ON.
state 5) Turn the steering wheel slowly.
Steering speed sensor Between SR3 (1) – (3) Voltage 10 – 13 V
3
defective
2) Disconnect connector SR3.
Between SR3 (2) – (3) Voltage See Fig-1.
2) Disconnect connectors BRC1, BRC2.
Between BRC1 (16) – BRC2
Voltage 10 – 13 V
(29)
4 Retarder controller defective
5) Turn the steering wheel slowly.
Between BRC2 (37) – (29) Voltage See Fig-1.
32 HD465-7R, HD605-7R
HD465-7R, HD605-7R 33
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) 1
Action code Failure code Pitch angle sensor: Out of input signal range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of Inclination sensor has become below 0.5 V or above 4.5 V.
Action of
Problem that
appears on • Machine pitch angle abnormality [989D00] cannot be detected.
machine
• Signal from Inclination sensor can be checked with monitoring function (Code: 32900 (°) and 32903
Related
(V)).
information
• Cannot detect tipping over.

2) Connect T-adapter to connector AS3 (male).
1 Defective pitch angle sensor 3) Turn starting switch ON.
Between AS3 (C) – (A) Voltage 20 – 30 V
Between AS3 (B) – (A) Voltage 0.5 – 4.5 V
2) Connect T-adapter to connectors ATC1 (female) and AS3
(female).
harness Max. 1 z
2 – AS3 (female) (B) tance
Max. 1 z
– AS3 (female) (C) tance
Max. 1 z
– AS3 (female) (A) tance
Possible causes 2) Disconnect connectors ATC1 and AS3.
and standard 3) Connect T-adapter to ATC1 (female).
value in normal
state Defective harness grounding Resis-
3 between ATC1 (female) (19) – AS3 (female) Min. 1 Mz
(B)
Resis-
between ATC1 (female) (16) – AS3 (female) Min. 1 Mz
tance
(C)
2) Disconnect connectors ATC1 and AS3.
Defective hot short in wiring 3) Connect T-adapter to ATC1 (female).
4 harness 4) Turn starting switch ON.
(Contact with 24 V circuit) Between ground and wiring harness
between ATC1 (female) (19) – AS3 (female) Voltage Max. 4.6 V
(B)
2) Connect T-adapter in connector ATC1.
Defective transmission 3) Turn starting switch ON.
5
controller
Between ATC1 (female) (16) – (21) Voltage 20 – 30 V
Between ATC1 (female) (19) – (21) Voltage 0.5 – 4.5 V
34 HD465-7R, HD605-7R
HD465-7R, HD605-7R 35
Failure code [DKH1KX] (Pitch angle sensor: Abnormality

(Disconnection or short circuit)) 1
Action code Failure code Pitch angle sensor: Abnormality (Disconnection or short circuit)
Trouble
E01 DKH1KX (VHMS & PLM controller system)
Contents of
• Abnormality (Disconnection or short circuit) was detected in signal from pitch angle sensor.
trouble
Action of • None in particular.
controller • Cannot detect tipping over.
Problem that
appears on • Load weight is not displayed or recorded correctly.
machine
Related • Input signal from pitch angle sensor can be checked with monitoring function (Code: 32901 (°),
information 32902 (V)).

and standard
value in normal Carry out troubleshooting for failure code [DKH0KX].
state
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [DLF1KA] (Transmission input shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E03 DLF1KA (Transmission controller system)
Contents of • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not
trouble input.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
• The lockup system is reset and the gear cannot be shifted.
appears on
Related
• This failure can be checked in the monitoring function (Code: 31200 (rpm)).
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission input shaft
a For details, see Testing and adjusting, "Adjustment of transmis-
speed sensor
sion speed sensor".
Defective transmission input
2 Resis- 500 –
shaft speed sensor Between CN3 (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors ATC2 and CN3.
harness
contact)
Max. 1 z
4
troller
Resis- 500 –
Between ATC2 (female) (40) – (29)
tance 1,000 z
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39

Disagreement of revolution speed signal) 1
Action code Failure code Transmission input shaft speed sensor: Disagreement of revolution
Trouble speed signal
E03 DLF1LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed
Contents of
sensor signal, and transmission output shaft speed sensor signal is different from the signal speed
trouble
of the transmission input shaft speed sensor.
Problem that
appears on
Related
information

Defective transmission input
1 Resis- 500 –
shaft speed sensor Between CN3 (male) (1) – (2)
tance 1,000 z
Resis-
tance
Grounding fault in wiring 3) Connect T-adapter.
2 harness
Possible causes
and standard between ATC2 (female) (40) – CN3 (female) Min. 1 Mz
(1)
state
between ATC2 (female) (40) – CN3 (female) Voltage Max. 1 V
(1)
4
troller
Resis- 500 –
tance 1,000 z
40 HD465-7R, HD605-7R
HD465-7R, HD605-7R 41
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA (Transmission controller system)
Contents of • The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals
trouble are not input.
Problem that
appears on
Related
information

Wrong adjustment of
1 transmission intermediate
shaft speed sensor
sion speed sensor".
Defective transmission inter-
2 Resis- 500 –
mediate shaft speed sensor Between CN4 (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors ATC2, CN4.
harness
contact)
Max. 1 z
4
troller
Resis- 500 –
tance 1,000 z
42 HD465-7R, HD605-7R
HD465-7R, HD605-7R 43

Action code Failure code Transmission intermediate shaft speed sensor: Disagreement of
Trouble revolution speed signal
E03 DLF2LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from the signal speed of the
trouble
transmission intermediate shaft speed sensor.
Problem that
appears on
Related
information

Transmission intermediate
1 Resis- 500 –
shaft speed sensor defective Between CN4 (male) (1) – (2)
tance 1,000 z
Resis-
tance
2) Disconnect connectors ATC2 – CN4.
2 harness
Possible causes
and standard between ATC2 (female) (20) – CN4 (female) Min. 1 Mz
(1)
state
(1)
4
troller
Resis- 500 –
tance 1,000 z
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45

© 2007 KOMATSU
All Rights Reserved
46 HD465-7R, HD605-7R
SEN02539-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear)).................................................... 4
Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear)) .................................................... 6
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear)) .............................................................. 8
Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear)) ................................................... 9
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear)) .................................................... 10
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear)) ............................................................... 12
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear)) ............................................................... 14
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear)) ................................................... 15
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ...................................... 16
Disagreement of revolution speed signal) ............................................................................................. 18
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) ...................................... 20
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) .......................................... 22
Failure code [DV00KB] (Buzzer output: Short circuit)................................................................................... 24
Failure code [DW2AKA] (Main pressure variable valve output: Disconnection) ........................................... 26
Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault).................................... 28
HD465-7R, HD605-7R 1
Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short) ......................................... 30
Failure code [DW2AL1] (Main pressure variable valve: Defective reset)...................................................... 32
Failure code [DW2ALH] (Main pressure variable valve: Malfunction)........................................................... 34
Disconnection or short circuit)................................................................................................................ 36
Disconnection or short circuit) (If equipped) .......................................................................................... 38
Failure code [DW72KZ] (Kick-out solenoid output system trouble: Disconnection or short circuit) .............. 40
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)........... 42
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble:
Disconnection or short circuit)................................................................................................................ 44
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating)) .......................................... 46
Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection) ................................................ 48
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault) ................................................... 50
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit) .................................................... 52
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate))........................................ 53
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Failure code [DLF8KA] (Wheel speed sensor: Disconnection

(Right rear)) 1
Action code Failure code Wheel speed sensor: Disconnection (Right rear)
Trouble
E01 DLF8KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
• Does not control ASR.
controller
Problem that
appears on • ASR is not controlled normally.
machine
• ABS controller inspects same trouble by failure code [DLF8MA].
a If ABS is installed and [DLF8MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF8MA] is displayed, perform following operations.
Related
information
2) Disconnect ABS7 connector.
Check that failure code [DLF8KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.

a Turn starting switch OFF and disconnect WSRR, then carry out
Defective wheel speed
1
sensor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Possible causes harness
Between WSRR (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring Max. 1 z
(female) (10) tance
value in normal or defective contact in
state connector) Between WSRR (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
Grounding fault in wiring troubleshooting without turning starting switch ON.
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
If causes 1 – 3 are not detected, retarder controller may be
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [DLF8L3] (Wheel speed sensor: Disconnection

(Right rear)) 1
Trouble
E03 DLF8L3 (ABS controller system)
Contents of
• Wheel speed signal (pulse) input to ABS controller is abnormal.
trouble
Action of
• Does not control ABS.
controller
Problem that
• ABS is not controlled normally.
appears on
• (Retarder is not controlled normally.)
machine
• Retarder controller inspects same trouble by failure code [DLF8LC].
Related a If [DLF8L3] is not displayed, sensor and wiring harness out of cab are judged normal.
information a If [DLF8LC] is displayed, disconnect BRC2 connector and check that [DLF8L3] is displayed
again and then carry out following troubleshooting.

1
sensor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRR, ABS2
Disconnection in wiring conector, then carry out troubleshooting without turning starting
switch ON.
and standard 2 (Disconnection in wiring Between WSRR (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (20) tance
state connector)
Between WSRR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
6 HD465-7R, HD605-7R
HD465-7R, HD605-7R 7
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear)) 1

Action code Failure code Wheel speed sensor: Trouble (Right rear)
Trouble
E01 DLF8LC (Retarder controller system)
Contents of
• Wheel speed signal (pulse) input to retarder controller is abnormal.
trouble
Action of
• Does not control retarder.
controller
Problem that
machine
• ABS controller inspects same trouble by failure code [DLF8L3].
a If ABS is installed and [DLF8L3] is not displayed, sensor and wiring harness out of cab are
Related
judged normal.
information
a If ABS is installed and [DLF8L3] is displayed, turn starting switch OFF and disconnect ABS7
connector. Check that failure code [DLF8LC] is displayed again.

and standard
value in normal Carry out troubleshooting for failure code [DLF8KA].
state
8 HD465-7R, HD605-7R
Failure code [DLF8MA] (Wheel speed sensor: Disconnection

(Right rear)) 1
Trouble
E03 DLF8MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
appears on • ABS is not controlled normally.
machine
• Retarder controller inspects same trouble by failure code [DLF8KA].
Related a If [DLF8KA] is not displayed, sensor and wiring harness out of cab are judged normal.
information a If [DLF8KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
BRC2 connector. Check that failure code [DLF8MA] is displayed again.

and standard
value in normal Carry out troubleshooting for failure code [DLF8L3].
state
HD465-7R, HD605-7R 9
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear))1

Action code Failure code Wheel speed sensor: Disconnection (Left rear)
Trouble
E01 DLF9KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
controller
Problem that
• ASR is not controlled normally.
appears on
• (ABS is not controlled normally.)
machine
• ABS controller inspects same trouble by failure code [DLF9MA].
a If ABS is installed and [DLF9MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF9MA] is displayed, perform following operations.
Related
information
2) Disconnect ABS7 connector.
Check that failure code [DLF9KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.

a Turn starting switch OFF and disconnect WSRL, then carry out
Defective wheel speed troubleshooting without turning starting switch ON.
1
sensor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Between WSRL (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring or Max. 1 z
(female) (20) tance
value in normal defective contact
state in connector) Between WSRL (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear)) 1

Action code Failure code Wheel speed sensor: Trouble (Left rear)
Trouble
E03 DLF9L3 (ABS controller system)
Contents of
trouble
Action of
controller
Problem that
appears on • ABS is not controlled normally.
machine
• Retarder controller inspects same trouble by failure code [DLF9LC].
Related a If [DLF9LC] is not displayed, sensor and wiring harness out of cab are judged normal.
information a If [DLF9LC] is displayed, disconnect BRC2 connector and check that [DLF9L3] is displayed
again and then carry out following troubleshooting.

1
sensor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRL and
Disconnection in wiring ABS2 connectors, then carry out troubleshooting without turn-
ing starting switch ON.
and standard 2 (Disconnection in wiring Between WSRL (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (11) tance
state connector) Between WSRL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
carried out.)
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear)) 1

Action code Failure code Wheel speed sensor: Trouble (Left rear)
Trouble
E01 DLF9LC (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
• ASR is not controlled normally.
appears on
• (ABS is not controlled normally.)
machine
• ABS controller inspects same trouble by failure code [DLF9L3].
a If ABS is installed and [DLF9L3] is not displayed, sensor and wiring harness out of cab are
Related
judged normal.
information
a If ABS is installed and [DLF9L3] is displayed, turn starting switch OFF and disconnect ABS7
connector. Check that failure code [DLF9LC] is displayed again.

and standard
value in normal Carry out troubleshooting for failure code [DLF9KA].
state
14 HD465-7R, HD605-7R
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear))1

Action code Failure code Wheel speed sensor: Disconnection (Left rear)
Trouble
E03 DLF9MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
• ABS is not controlled normally.
appears on
• (Retarder is not controlled normally.)
machine
• Retarder controller inspects same trouble by failure code [DLF9KA].
Related a If [DLF9KA] is not displayed, sensor and wiring harness out of cab are judged normal.
information a If [DLF9KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
BRC2 connector. Check that failure code [DLF9MA] is displayed again.

and standard
value in normal Carry out troubleshooting for failure code [DLF9L3].
state
HD465-7R, HD605-7R 15
Failure code [DLT3KA] (Transmission output shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
trouble input.
• Keeps gear speed when trouble occurs.
Action of
• If gearshift lever is set in "N", gear is kept in neutral.
controller
• Turns lockup system OFF.
1) Stop travel and set gearshift lever in "N" position.
2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
Problem that other to set machine in emergency escape mode.
appears on 3) Operate gearshift lever and start machine again.
machine
• When operating gearshift lever, release accelerator pedal.
• Operate gearshift lever from N to D – L or from N to R.
• Machine is kept in emergency escape mode until starting switch is turned OFF.
Related
information

Wrong adjustment of
1 transmission output shaft
speed sensor
sion speed sensor".
2 Resis- 500 –
output shaft speed sensor Between CN5 (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors BRC2, ATC2, CN5.
Disconnection in wiring 3) Connect T-adapter to ATC2 (female) and CN5 (female).
harness
contact)
Max. 1 z
2) Disconnect connectors BRC2, ATC2.
Defective ransmission 3) Connect T-adapter to ATC2 (female).
4
controller
Resis- 500 –
tance 1,000 z
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17

Action code Failure code Transmission output shaft speed sensor: Disagreement of revolu-
Trouble tion speed signal
E03 DLT3LC (Retarder controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of
trouble
the transmission output shaft speed sensor.
Problem that
appears on
machine • If the shift lever is set in the "N" position, the gear is set in neutral.
Related
information

1 Resis- 500 –
tance 1,000 z
Between CN5 (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, and CN5.
Possible causes 2 harness
and standard (Contact with ground circuit) Between ground and wiring harness Resis-
value in normal between ATC2 (female) (30) – BRC2 Min. 1 Mz
tance
state (female) (30) – CN5 (female) (1)
2) Disconnect connectors ATC2, BRC2, CN5.
Wiring harness between ATC2 (female) (30)
Voltage Max. 1 V
– BRC2 (female) (30) – CN5 (female) (1)
Defective transmission 3) Connect T-adapter.
4
controller
Resis- 500 –
tance 1,000 z
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [DLT4KA] (Transmission output shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT4KA (Retarder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• Turns output to ASR proportional solenoid OFF.
Action of • Turns output to auto-suspension solenoid OFF.
controller • When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
• ARSC control cannot be continued. (Even if ARSC switch ON with ARSC selection.)
• ASR control cannot be continued.
1) Stop travel and set gearshift lever in "N" position.
Problem that
2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
appears on
other to set machine in emergency escape mode.
machine
3) Operate gearshift lever and start machine again.
• When operating gearshift lever, release accelerator pedal.
• Operate gearshift lever from N to D – L or from N to R.
• Machine is kept in emergency escape mode until starting switch is turned OFF.
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (V), 31403
Related
(rpm)). Wheel speed can be also checked with monitoring function (Code: 39704 (rpm)).
information
• Controller does not defect ground fault and hot short.

Wrong adjustment of
then return it by 1/2 - 1 turn.
speed sensor
sion speed sensor".
Defective transmission Resis- 500 –
2 Between CN5 (male) (1) – (2)
output shaft speed sensor tance 1,000 z
Resis-
Possible causes Between CN5 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
state 2) Disconnect connectors ATC2, BRC2, and CN5.
Disconnection in wiring 3) Connect T-adapter to BRC2 (female) and CN5 (female).
harness
3 Wiring harness between BRC2 (female) (30) Resis-
contact)
Max. 1 z
2) Disconnect connectors BRC2 and ATC2.
4 Defective reterder controller 3) Connect T-adapter to BRC2 (female).
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [DLT4MA] (Transmission output shaft speed sensor:

Malfunction) 1
Action code Failure code Transmission output shaft speed sensor: Defective function
Trouble
E03 DLT4MA (Reterder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• ASR control released.
• Turns output to ASR proportional solenoid OFF.
Action of
controller • Turns output to auto-suspension solenoid OFF.
• When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
Problem that
• ARSC control cannot be continued.
appears on
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (rpm),
Related
31403 (rpm)). Wheel speed can be also checked with monitoring function (Code: 39704 (rpm),
information
39705 (rpm)).

Wrong adjustment of
then return it by 1/2 - 1 turn.
speed sensor
sion speed sensor".
2 Resis- 500 –
tance 1,000 z
Resis-
tance
Possible causes Defective transmission Resis- 500 –

3 Between CN5 (male) (1) – (2)
and standard output shaft speed sensor tance 1,000 z
value in normal Resis-
state tance
2) Disconnect connectors ATC2, BRC2, PM5, and CN5.
Grounding fault in wiring 3) Connect T-adapter to BRC2 (female).
4 harness Between ground and wiring harness
(Contact with ground circuit) between BRC2 (female) (30) – ATC2 Resis-
Min. 1 Mz
(female) (30) – PM5 (female) (7) – CN5 tance
(female) (1)
2) Disconnect connectors BRC2, ATC2, PM5, and CN5.
Disconnect hot short in 4) Turn the starting switch ON.
5 wiring harness
between ATC2 (female) (30) – BRC2
Voltage Max. 1 V
(female) (30) – PM5 (female) (7) – CN5
(female) (1)
22 HD465-7R, HD605-7R

and standard 2) Disconnect connector BRC2 and ATC2.
value in normal 6 Defective reterder controller 3) Connect T-adapter.
state Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
HD465-7R, HD605-7R 23
Failure code [DV00KB] (Buzzer output: Short circuit) 1

Action code Failure code Buzzer output: Short circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• When signal is output to buzzer circuit, abnormal current flows.
trouble
Action of • Keeps abnormality until starting switch is turned OFF.
machine moniter • Turns alarm buzzer output OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
Related • If buzzer sounds, BZ2 (2) is Sink output (Normal).
information • Controller cannot detect disconnection and ground fault of wiring harness.

1) Turn starting switch OFF, disconnect connector BZ2, and
remove buzzer.
1 Defective buzzer 2) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2
(male) (2).
a If buzzer does not sound, buzzer is defective. (Replace)
a Turn starting switch OFF and disconnect BZ2, then carry out
2 harness
(Contact with ground circuit) Between DPC1 (male) (13) – ground Resis-
Min. 1 Mz
tance
Possible causes 1) Turn starting switch OFF, disconnect DPC1 and BZ2, and insert
Hot short T-adapter in DPC1 (female).
and standard
3 (Contact with 24V circuit) in 2) Turn starting switch ON and carry out troubleshooting.
value in normal
wiring harness
state Between DPC1 (male) (13) – ground Voltage Max. 1 V
Disconnection in wiring without turning starting switch ON. (When voltage in Cause 1 is
harness abnormal)
4 (Disconnection in wiring or Resis-
Between DPC1 (female) (13) – BZ2 (2) Max. 1 z
defective contact in tance
connector) Resis-
Between BT2 (16) – BZ2 (1) Max. 1 z
tance
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [DW2AKA] (Main pressure variable valve output:

Disconnection) 1
Action code Failure code Main pressure variable valve output: Disconnection
Trouble
E01 DW2AKA (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to main pressure variable valve solenoid circuit.
controller
Problem that
appears on • If the machine keeps traveling as it is, fuel consumption increases.
machine
• Output state to main pressure variable valve solenoid can be checked with monitoring function
Related (Code: 31643 (mA)).
information • Signal is not output to main pressure variable valve solenoid circuit until starting switch is turned
OFF once.

Defective main pressure without turning starting switch ON.
1 variable valve solenoid
CN27 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible causes
and standard Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON. (When check result of Cause
state 2 (Disconnection in wiring 1 is normal)
or defective contact in Resis-
connector) Between ATC3 (female) (13) – (37) 5 – 15 z
tance
If causes 1 and 2 are not detected, transmission controller may be
3 defective. (Since trouble is in system, troubleshooting cannot be
controller
carried out.)
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
Failure code [DW2AKB] (Main pressure variable valve output circuit:

Ground fault) 1
Action code Failure code Main pressure variable valve output circuit: Ground fault
Trouble
E01 DW2AKB (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of • Stops outputting signal to main pressure variable valve solenoid circuit.
controller • Limits operation of engine and transmission.
Problem that
machine
OFF once.

1 variable valve solenoid
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect CN27, then carry out
2 harness
(Contact with ground circuit) Between ATC3 (female) (37) – ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect CN27, then carry out
Short circuit in wiring troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between ATC3 (female) (37) Resis-
Min. 1 Mz
– ATC3 (female) (pin other than 37) tance
a Turn starting switch OFF and insert T-adapter in ATC3, then turn
Hot short (Contact with 24 V starting switch ON and carry out troubleshooting.
4
Between ATC3 (female) (37) – ground Voltage Max. 1 V
If causes 1 – 4 are not detected, transmission controller may be
controller
carried out.)
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [DW2AKY] (Main pressure variable valve output circuit:

Hot short) 1
Action code Failure code Main pressure variable valve output circuit: Hot short
Trouble
E01 DW2AKY (Transmission controller system)
Contents of
• While signal is not output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
• Error [15*OMW] may be detected because of oil pressure reduction.
appears on
machine • The transmission clutch may be damaged during travel in F1, F2 or F3.
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AKB].
state
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31
Failure code [DW2AL1] (Main pressure variable valve: Defective reset) 1

Action code Failure code Main pressure variable valve: Defective reset
Trouble
E01 DW2AL1 (Transmission controller system)
Contents of • When outputting signal to main pressure variable valve solenoid circuit is stopped, response of
trouble main pressure switch is abnormal.
Action of
controller
Problem that
• Error [15*OMW] may be detected because of oil pressure reduction.
appears on
machine • The transmission clutch may be damaged during travel in F1, F2 or F3.
OFF once.

1 switch
Between (1) – (2) Max. 10 z
Defective main pressure Main pressure variable valve may have mechanical trouble.
2
variable valve Check it directly.
3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
Possible causes Grounding fault in wiring troubleshooting without turning starting switch ON.
and standard 4 harness
(Contact with ground circuit) Between ATC2 (female) (7) – ground Resis-
value in normal Min. 1 Mz
tance
state
Short circuit in wiring troubleshooting without turning starting switch ON.
5 harness
(with another wiring harness) Wiring harness between ATC2 (female) (7) Resis-
Min. 1 Mz
– ATC (female) (pin other than 7) tance
a Turn starting switch OFF and insert T-adapter in ATC2, then turn
Hot short (Contact with 24 V starting switch ON and carry out troubleshooting.
6
Between ATC2 (female) (7) – ground Voltage Max. 1 V
If causes 1 – 6 are not detected, transmission controller may be
controller
carried out.)
32 HD465-7R, HD605-7R
HD465-7R, HD605-7R 33
Failure code [DW2ALH] (Main pressure variable valve: Malfunction) 1

Action code Failure code Main pressure variable valve: Malfunction
Trouble
E01 DW2ALH (Transmission controller system)
Contents of • When signal is output to main pressure variable valve solenoid circuit, main pressure switch does
trouble not respond.
Action of
controller
Problem that
machine
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AL1].
state
34 HD465-7R, HD605-7R
HD465-7R, HD605-7R 35
Failure code [DW35KZ] (Failure in output system of auto suspension

solenoid 1: Disconnection or short circuit) 1
Action code Failure code Failure in output system of auto suspension solenoid 1: Disconnec-
Trouble tion or short circuit
E01 DW35KZ (Retarder controller system)
Contents of • When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S04.
Defective auto suspension
1 Resis-
solenoid 1 Between S04 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S04 (female) (1), (2) – ground Min. 1 Mz
tance
harness
Possible causes 2 Wiring harness between BRC3 (female) (7) Resis-
and standard – S04 (female) (1) tance
contact)
value in normal Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S04 (female) (2) tance
2) Disconnect BRC3 and S04.
Hot short in wiring harness 3) Connect T-adapter to BRC3 (female).
Wiring harness between BRC3 (female) (7)
Voltage Max. 1 V
– S04 (female) (1)
Resis-
Between BRC3 (female) (7) – ground 15 – 35 z
tance
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [DW36KZ] (Failure in output system of auto suspension

solenoid 2: Disconnection or short circuit) (If equipped) 1
Action code Failure code Failure in output system of auto suspension solenoid 2: Disconnec-
Trouble tion or short circuit
Contents of • When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S05.
Defective auto suspension
1 Resis-
solenoid 2 Between S05 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S05 (female) (1), (2) – ground Min. 1 Mz
tance
harness
Possible causes 2 Wiring harness between BRC3 (female) (37) Resis-
and standard – S05 (female) (1) tance
contact)
value in normal Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S05 (female) (2) tance
2) Disconnect BRC3 and S05.
Voltage Max. 1 V
– S05 (female) (1)
Resis-
Between BRC3 (female) (37) – ground 15 – 20 z
tance
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39
Failure code [DW72KZ] (Kick-out solenoid output system trouble:

Disconnection or short circuit) 1
Action code Failure code Kick-out solenoid output system trouble: Disconnection or short
Trouble circuit
Contents of • When signal is output to hoist lever kick-out solenoid circuit, large current flows or no current flows
trouble or when signal is not output, some current flows.
Action of
• Turns output to hoist lever kick-out solenoid OFF.
controller
Problem that
appears on • Hoist lever is not locked by detent.
machine
• This phenomenon also occurs when signals from body potentiometer and sensor are abnormal.
Related
(See failure code DK54KX.)
information
• When kick-out solenoid needs to be replaced, hoist lever must be replaced.

2) Disconnect connector BRC3 and LK0.
harness
1 Wiring harness between LK0 (female) (2) – Resis-
ground tance
contact)
Max. 1 z
– LK0 (female) (1) tance
2) Disconnect connector BRC3 and LK0.
Possible causes (Contact with 24V circuit)
and standard Wiring harness between BRC3 (female) (27)
Voltage Max. 1 V
value in normal – LK0 (female) (1)
state 1) Turn the starting switch OFF.
2) Disconnect connector LK0.
Defective hoist lever kick-out
3 Resis- 39 z ±
solenoid Between LK0 (male) (1) – (2)
tance 5%
Resis-
Between LK0 (male) (1) and (2) – ground Min. 1 Mz
tance
Resis- 39 z ±
Between BRC3 (female) (27) – ground
tance 5%
40 HD465-7R, HD605-7R
HD465-7R, HD605-7R 41
Failure code [DW73KZ] (Failure in hoist select valve output system:

Disconnection or short circuit) 1
Action code Failure code Failure in hoist select valve output system: Disconnection or short
Trouble circuit
Contents of • When the output to the hoist lever select valve solenoid circuit is ON, a too large current flows or
trouble any current does not flow. Or, some current is flowing while the output is OFF.
Action of • The controller turns the output to the hoist lever select valve solenoid OFF.
controller • The controller turns the output to the hoist lever EPC valve solenoid OFF.
Problem that
machine
Related
information

2) Disconnect connectors BRC3 and HSOL.
harness
– HSOL (female) (B) tance
contact)
Max. 1 z
– HSOL (female) (A) tance
2) Disconnect connectors BRC3 and HSOL.
Defective hot short in wiring 3) Connect T-adapter to BRC3 (female).
Possible causes (Contact with 24V circuit) Between ground and wiring harness
and standard
between BRC3 (female) (17) – HSOL Voltage Max. 1 V
value in normal
(female) (A)
state
2) Disconnect connector HSOL.
Defective hoist lever select
3 Resis-
valve solenoid Between HSOL (male) (A) – (B) 15 – 35 z
tance
Resis-
Between HSOL (male) (A), (B) – ground Min. 1 Mz
tance
2) Disconnect connector HSOL.
Resis-
Between BRC3 (female) (17) – (13) 15 – 35 z
tance
42 HD465-7R, HD605-7R
HD465-7R, HD605-7R 43
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output
system trouble: Disconnection or short circuit) 1
Action code Failure code Brake cooling valve (BCV) (rear wheel) output system trouble:
Trouble Disconnection or short circuit
Contents of • Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned
trouble ON/OFF. Accordingly, BCV solenoid cannot be driven.
Action of • Stops supplying current when BCV circuit is disconnected.
controller • Turns output to BCV relay (R14) primary side OFF.
Problem that
appears on • Since retarder is not cooled, it may overheat.
machine
Related
• For troubleshooting for BCV relay (R14) secondary side, see [B@C7NS].
information

carry out troubleshooting without turning starting switch ON.
1 Defective R14 (BCV relay) R14
Resistance
(female: Wiring harness side)
Between (1) – (2) 100 – 500 z
Grounding fault in wiring carry out troubleshooting without turning starting switch ON.
2 harness
(Contact with ground circuit) Between R14 (female) (1) – ground Min. 1 Mz
and standard tance
value in normal
a Turn starting switch OFF and disconnect R14 (BCV relay) and
state
Disconnection in wiring BRC3, then carry out troubleshooting without turning starting
harness switch ON.
3 (Disconnection in wiring Between BRC3 (female) (18) – R14 Resis-
Max. 1 z
or defective contact in (female) (1) tance
connector) Resis-
Between ER1 (ground) – R14 (female) (2) Max. 1 z
tance
out.)
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps

operating)) 1
Action code Failure code ASR shut-off valve: Trouble (Valve keeps operating)
Trouble
E01 DWNBK4 (Retarder controller system)
Contents of
• ASR pressure sensor does not respond to shut-off valve OFF command of retarder controller.
trouble
Action of
• Stops controlling ASR.
controller
Problem that
machine
• ASR pressure sensor is turned OFF when pressure is 0.3 MPa {3 kg/cm²} or less. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

a ASR shut-off valve may have mechanical trouble. Check it
directly.
1 Defective ASR shut-off valve 1) Turn starting switch ON.
2) Turn ASR switch ON/OFF.
Operating sound of ASR shut-off valve solenoid is heard.
2) Disconnect ASR7.
3) Prepare and turn starting switch ON.
4) Turn ASR switch ON and OFF and carry out troubleshooting.
Defective ASR pressure
2 Both ends of jig: Between ASR7
sensor Resistance
(male) (1) – ASR7 (male) (2)
Possible causes Turn ASR switch OFF Min. 1 Mz
and standard
Turn ASR switch ON Max. 1 z
value in normal
state a Turn starting switch OFF and disconnect ASR7 and BRC3, then
Disconnection in wiring carry out troubleshooting without turning starting switch ON.
harness
Between ASR7 (female) (1) – BRC3 Resis-
3 (Disconnection in wiring or Max. 1 z
(female) (30) tance
defective contact in connec-
tor) Between ASR7 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
(Contact with ground circuit) Between ASR7 (female) (1) – ground Resis-
Min. 1 Mz
tance
out.)
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47
Failure code [DWNBKA] (ASR shut-off valve output circuit:

Disconnection) 1
Action code Failure code ASR shut-off valve output circuit: Disconnection
Trouble
E01 DWNBKA (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, no current flows.
trouble
Action of
controller
Problem that
machine
Related
• Signal is not output to ASR shut-off valve solenoid circuit until starting switch is turned OFF once.
information

Defective ASR shut-off valve without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring without turning starting switch ON. (When check result of Cause
value in normal harness 1 is normal)
state 2 (Disconnection in wiring Resis-
Between J04 (male) (42) – (43) 5 – 15 z
or defective contact in tance
connector) Resis-
tance
If causes 1 and 2 are not detected, retarder controller may be
carried out.)
48 HD465-7R, HD605-7R
HD465-7R, HD605-7R 49
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground

fault) 1
Action code Failure code ASR shut-off valve output circuit: Ground fault
Trouble
E01 DWNBKB (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

Defective ASR shut-off valve troubleshooting without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
(Internal short circuit)
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect BRC3 and ASR2, then
2 harness
(Contact with ground circuit) Between BRC3 (female) (15) – ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect BRC3 and ASR2, then
Short circuit in wiring carry out troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
(15) – BRC3 (female) (pin other than (15)) tance
a Turn starting switch OFF and insert T-adapter in BRC3, then
Hot short (Contact with 24 V turn starting switch ON and carry out troubleshooting.
4
Between BRC3 (female) (15) – ground Voltage Max. 1 V
out.)
50 HD465-7R, HD605-7R
HD465-7R, HD605-7R 51
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short

circuit) 1
Action code Failure code ASR shut-off valve output circuit: Short circuit
Trouble
E01 DWNBKY (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting for failure code [DWNBKB].
state
52 HD465-7R, HD605-7R
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not
operate)) 1
Action code Failure code ASR shut-off valve: Trouble (Valve does not operate)
Trouble
E01 DWNBKY (Retarder controller system)
Contents of
• ASR pressure sensor does not respond to shut-off valve ON command of retarder controller.
trouble
Action of
controller
Problem that
• Retarder is not controlled normally.
appears on
machine • ASR is not controlled normally.
• ASR pressure sensor is turned ON when pressure is 0.7 MPa {7 kg/cm²} or above. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

and standard
value in normal Carry out troubleshooting for failure code [DWNBK4].
state
HD465-7R, HD605-7R 53

© 2007 KOMATSU
All Rights Reserved
54 HD465-7R, HD605-7R
SEN02540-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control).............. 4
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection) ......................................................................................................................................... 6
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) ................ 7
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line) ........................................................................................................... 8
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) ................ 9
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) .................................................. 10
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) ..................................................... 12
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) ................. 14
Failure code [DX17K4] (ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating)) ........................................................................................................... 16
Failure code [DX17KA] (ASR proportional pressure reducing solenoid valve (right) output circuit:
Disconnection) ....................................................................................................................................... 18
Failure code [DX17KB] (ASR proportional pressure reducing solenoid valve (right) output circuit:
Ground fault).......................................................................................................................................... 20
HD465-7R, HD605-7R 1
Failure code [DX17KY] (ASR proportional pressure reducing solenoid valve (right) output circuit:
Short circuit)........................................................................................................................................... 22
Failure code [DX17MA] (ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate)).......................................................................................................... 22
Failure code [DX18K4] (ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating)) ........................................................................................................... 24
Failure code [DX18KA] (ASR proportional pressure reducing solenoid valve (left) output circuit:
Disconnection) ....................................................................................................................................... 26
Failure code [DX18KB] (ASR proportional pressure reducing solenoid valve (left) output circuit:
Ground fault) .......................................................................................................................................... 28
Failure code [DX18KY] (ASR proportional pressure reducing solenoid valve (left) output circuit:
Short circuit)........................................................................................................................................... 30
Failure code [DX18MA] (ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate)).......................................................................................................... 30
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Failure code [DX11K4] (Rear brake proportional pressure reducing

solenoid valve: Out of control) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX11K4 (Valve is stuck in operated condition)
Contents of • Rear brake proportional pressure reducing solenoid valve is stuck in operated condition (does not
trouble move).
Action of
• Continues control.
controller
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related • Retarder oil pressure switch state can be checked with monitoring function (Code: 40932)
information (bit [3], 0:OFF, 1:ON).

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
Defective rear brake 2) Disconnect connector REVR.
2 proportional pressure
reducing solenoid Resis-
Between REVR (male) (1) – (2) 20 z
tance
2) Insert T-adapter in connector RESW.
3) Start engine.
Defective retarder pressure
3 RESW Retarder Voltage
switch
Possible causes When not operated 20 – 30 V
and standard Between (A) – (B)
When operated Max. 1 V
value in normal
2) Disconnect connectors BRC1 and RESW.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
between BRC1 (female) (5) – RESW Min. 1 Mz
tance
(female) (A)
Oil
pressure Voltage Max. 1 V
is ON.
Between BRC3 (16) – (13)
Oil
pressure Voltage 20 – 30 V
is OFF.
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
Failure code [DX11KA] (Rear brake proportional pressure reducing

solenoid valve output circuit: Disconnection) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve output
Trouble circuit: Disconnection
E03 DX11KA (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (rear brake) does not operate.
machine
Related
information

2) Connect T-adapter to connector REVR (male).
Defective rear brake
Resis-
1 proportional pressure Between REVR (male) (1) – (2) 10 – 30 z
tance
reducing solenoid valve
Resis-
Between REVR (female) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Connect T-adapter to connectors BRC3 (female) and REVR
value in normal Disconnection in wiring (female).
state harness
2 Wiring harness between BRC3 (female) Resis-
(16) – REVR (female) (1) tance
contact)
Max. 1 z
(13) – REVR (female) (2) tance
Resis-
tance
6 HD465-7R, HD605-7R
Failure code [DX11KB] (Rear brake proportional pressure reducing

solenoid valve: Short circuit) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit
E03 DX11KB (Retarder controller system)
Contents of • When output to solenoid circuit of rear brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of rear brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
Between REVR (male) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC3 and REVR.
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground between BRC3 (female) (16) – REVR Min. 1 Mz
2 tance
circuit or contact between (female) (1)
harnesses) Between wiring harness from BRC3
(female) (16) – REVR (female) (1) and wir- Resis-
Min. 1 Mz
ing harness from BRC3 (female) (13) – tance
REVR (female) (2)
Resis-
tance
HD465-7R, HD605-7R 7
Failure code [DX11KY] (Rear brake proportional pressure reducing

solenoid valve: Short circuit to power source line) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
E03 DX11KY (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
Between REVR (male) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Disconnect connectors BRC3 and REVR.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
(a contact with 24 V circuit)
between BRC3 (female) (16) – REVR Voltage Max. 1 V
(female) (1)
Resis-
tance
8 HD465-7R, HD605-7R
Failure code [DX11MA] (Rear brake proportional pressure reducing

solenoid valve: Malfunction) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Malfunction
E03 DX11MA (Retarder controller system)
• Rear brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
return or their condition cannot be judged normally because of defect in sensor switch after they
trouble
return.
Action of
• Continues control.
controller
Problem that
• If solenoid is defective, rear brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related • Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932)
information (bit [3], 0:OFF, 1:ON).

and standard
value in normal Carry out troubleshooting for failure code [DX11K4].
state
HD465-7R, HD605-7R 9
Failure code [DX13KA] (Output circuit of hoist EPC valve:

Disconnection) 1
Action code Failure code Output circuit of hoist EPC valve: Disconnection
Trouble
Contents of
• When the output to the hoist EPC solenoid circuit is ON, any current does not flow.
trouble
Action of • The controller turns the output to the hoist select valve solenoid OFF.
controller • The controller turns the output to the hoist EPC valve solenoid OFF.
Problem that
machine
Related
• This failure can be checked in the monitoring function (Code: 45600 (mA)).
information

2) Disconnect connector HEPC.
Defective hoist EPC valve
1 Resis-
solenoid Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (male) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Disconnect connectors BRC3 and HEPC.
value in normal Disconnection in wiring 3) Connect T-adapter.
state harness
– HEPC (female) (1) tance
contact)
Max. 1 z
(13) – HEPC (female) (2) tance
Resis-
tance
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)1
Action code Failure code Output circuit of hoist EPC valve: Short circuit
Trouble
Contents of
• When the output to the hoist EPC valve solenoid circuit is ON, a too large current flows.
trouble
Problem that
machine
Related
information

1 Resis-
solenoid Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (male) (1), (2) – ground Min. 1 Mz
tance
Possible causes 2) Disconnect connectors BRC3 and HEPC.
and standard 3) Connect T-adapter to BRC3 (female).
value in normal Grounding fault or short
state circuit in wiring harness Resis-
2 between BRC3 (female) (5) – HEPC Min. 1 Mz
(Contact with ground circuit tance
(female) (1)
or another wiring harness)
Resis-
– HEPC (female) (1) and between BRC3 Min. 1 Mz
tance
(female) (13) – HEPC (female) (2)
Resis-
tance
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit
with power source line) 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit with power source
Trouble line
Contents of
• While the output to the hoist EPC valve solenoid circuit is OFF, some large current is flowing.
trouble
Problem that
machine
Related
information

1 Resis-
solenoid Between HEPC (female) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (female) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC3 and HEPC.
Possible causes
and standard
value in normal Hot short in wiring harness
state Between ground and wiring harness
2 (Contact with 24V wiring
between BRC3 (female) (5) – HEPC Voltage Max. 1 V
harness)
(female) (1)
between BRC3 (female) (13) – HEPC Voltage Max. 1 V
(female) (2)
Resis-
tance
14 HD465-7R, HD605-7R
HD465-7R, HD605-7R 15
Failure code [DX17K4] (ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve keeps operating)) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve keeps operating)
E01 DX17K4 (Retarder controller system)
Contents of • ASR presure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (right) OFF command of retarder controller.
Action of
controller
Problem that
machine
• ASR presure sensor is turned OFF when pressure is 0.3 MPa {3 kg/cm²} or less. (In range of 0.3
Related MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],
[DX17KB] or [DX17KY] is output.

a ASR proportional pressure reducing solenoid valve (right) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (right) If the failure is repaired by replacing the ASR valve (right), the
ASR valve (right) is defective.
1)Turn starting switch OFF.
2) Disconnect ASR6 and insert T-adapter in ASR6 (male) (Keep
Defective ASR presure ASR6 (female) disconnected).
2 3) Turn starting switch both OFF and ON (Keep ASR switch OFF).
sensor
Between ASR6 (male) (1) – ASR6 (male) Resis-
Min. 1 Mz
Possible causes (2) tance
and standard a Turn starting switch OFF and disconnect ASR6 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
3 (Disconnection in wiring Max. 1 z
(female) (10) tance
or defective contact in
connector) Between ASR6 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17
Failure code [DX17KA] (ASR proportional pressure reducing solenoid

valve (right) output circuit: Disconnection) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit
information until starting switch is turned OFF once.
Defective ASR proportional a Turn starting switch OFF and disconnect ASR4, then carry out
pressure reducing solenoid troubleshooting without turning starting switch ON.
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal disconnection) Between (1) – (2) 20 z
Between J04 (male) (36) – (37) 20 z
connector) Resis-
Between BRC3 (female) (26) – (23) 20 z
tance
carried out.)
18 HD465-7R, HD605-7R
HD465-7R, HD605-7R 19
Failure code [DX17KB] (ASR proportional pressure reducing solenoid

valve (right) output circuit: Ground fault) 1
Trouble circuit: Ground fault
trouble abnormal current flows.
Action of
controller
Problem that
machine
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [DX17KY] (ASR proportional pressure reducing solenoid

valve (right) output circuit: Short circuit) 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX17KB].
state
Failure code [DX17MA] (ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve does not operate)) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve does not operate)
• ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve
Contents of
(right) ON
trouble
command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],

and standard
state
22 HD465-7R, HD605-7R
HD465-7R, HD605-7R 23
Failure code [DX18K4] (ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve keeps operating)) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve keeps operating)
Contents of • ASR presure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (left) OFF command of retarder controller.
Action of
controller
Problem that
machine
• ASR presure sensor is turned OFF when pressure is 0.3 MPa {3 kg/cm²} or less. (In range of 0.3
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

a ASR proportional pressure reducing solenoid valve (left) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (left) If the failure is repaired by replacing the ASR valve (left), the ASR
valve (left) is defective.
2) Disconnect ASR5 and insert T-adapter in ASR5 (male) (Keep
Defective ASR presure ASR5 (female) disconnected).
2 3) Turn starting switch both OFF and ON (Keep ASR switch OFF).
sensor
Between ASR5 (male) (1) – ASR5 (male) Resis-
Min. 1 Mz
Possible causes (2) tance
and standard a Turn starting switch OFF and disconnect ASR5 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
3 (Disconnection in wiring Max. 1 z
(female) (20) tance
or defective contact in
connector) Between ASR5 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
24 HD465-7R, HD605-7R
HD465-7R, HD605-7R 25
Failure code [DX18KA] (ASR proportional pressure reducing solenoid

valve (left) output circuit: Disconnection) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit until
information starting switch is turned OFF once.
1
valve (left) solenoid (Internal ASR3 (male) Resistance
disconnection) Between (1) – (2) 20 z
Between J04 (male) (38) – (39) 20 z
connector) Resis-
Between BRC3 (female) (36) – (23) 20 z
tance
carried out.)
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27
Failure code [DX18KB] (ASR proportional pressure reducing solenoid

valve (left) output circuit: Ground fault) 1
Trouble circuit: Ground fault
Action of
controller
Problem that
machine
1
valve (left) solenoid (Internal ASR3 (male) Resistance
short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [DX18KY] (ASR proportional pressure reducing solenoid

valve (left) output circuit: Short circuit) 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX18KB].
state
Failure code [DX18MA] (ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve does not operate)) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve does not operate)
Contents of • ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve (left)
trouble ON command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

and standard
state
30 HD465-7R, HD605-7R
HD465-7R, HD605-7R 31

© 2007 KOMATSU
All Rights Reserved
32 HD465-7R, HD605-7R
SEN02541-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ............................................. 3
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)................................................. 4
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line) ............... 5
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection) ..................................................... 6
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ......................................................... 8
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)...................... 10
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................................... 14
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit) ...................................................... 16
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line) ..................... 18
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) .................................................. 22
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit) ..................................................... 24
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line) .................... 26
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)................................................. 30
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit) .................................................... 32
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line) ................... 34
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection) ................................................. 38
HD465-7R, HD605-7R 1
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ..................................................... 40
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) .................... 42
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................................... 46
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)........................................................ 48
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)....................... 50
Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection) ................................................. 52
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)..................................................... 54
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line).................... 56
2 HD465-7R, HD605-7R
Failure code [DXH1KA] (Lockup clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lockup clutch solenoid output circuit: Disconnection
Trouble
E03 DXH1KA (Transmission controller system)
Contents of
trouble • When signal is output to lockup clutch solenoid, no current flows.
• Keeps gear speed used for travel.

Action of
controller • Turns lockup operation OFF.
Problem that • Lockup system does not operate.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• As solenoid detects disconnection while output is ON, be sure to turn output ON to check operation
after repair.
Related infor- • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
mation • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
ON, wait for 5 seconds without starting the engine.
• If trouble has not been repaired, error is detected again.

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN16
state harness
(Disconnection or improper Max. 1 z
contact)
Max. 1 z
3
controller Resis-
Between ATC3 (female) (35) – (23) 5 – 15 z
tance
HD465-7R, HD605-7R 3
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short

circuit) 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit
Trouble
E03 DXH1KB (Transmission controller system)
Contents of • When signal is output to lockup clutch solenoid, much current flows, or while signal is OFF, some
trouble current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Lockup system is kept OFF.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
value in normal Short circuit of harness
state (Contact with ground circuit Resis-
2 between ATC3 (female) (35) – CN16 Min. 1 Mz
or contact between har- tance
(female) (1)
nesses)
Between wiring harness from ATC3 (female)
Resis-
(35) – CN16 (female) (1) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (23) – CN16 (female) (2)
3
controller Resis-
tance
4 HD465-7R, HD605-7R
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short

circuit to power source line) 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit to power source
Trouble line
E03 DXH1KY (Transmission controller system)
Contents of
trouble • While output to lock-up clutch solenoid is OFF, electric current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Cannot change gear speed.
appears on • Keeps lockup OFF
machine • When gear shift lever is operated to N, machine cannot move off.
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA))

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
value in normal 3) Connect T-adapter to ATC3 (female).
2
between ATC3 (female) (35) – CN16 Voltage Max. 1 V
(female) (1)
3
controller Resis-
tance
HD465-7R, HD605-7R 5
Failure code [DXH2KA] (Hi clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Hi clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • No electric current flows when the output to Hi clutch ECMV is ON.
Action of
ure.
controller
Problem that
appears on • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
after repair.
Related infor- • Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).

Resis-
tance
Resis-
tance
state harness
(Disconnection or Max. 1 z
defective contact)
Max. 1 z
Defective transmission con- 2) Connect T-adapter to connector ATC3 (female).
3
troller Resis-
tance
6 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 7
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)1
Action code Failure code Hi clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to Hi clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
Related infor-
mation • Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA)).

Resis-
tance
Resis-
tance
Possible causes
and standard
Short circuit of harness 3) Connect T-adapter to ATC3 (female).
value in normal
state (Contact with ground circuit Between ground and wiring harness between Resis-
2 Min. 1 Mz
or contact between har- ATC3 (female) (26) – CN19 (female) (1) tance
nesses) Between wiring harness from ATC3 (female)
Resis-
tance
3
controller Resis-
tance
8 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 9
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit
to power source line) 1
Action code Failure code Hi clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Hi clutch ECMV is OFF, electric current flows.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
between ATC3 (female) (26) – CN19 Voltage Max. 1V
(female) (1)
3
controller Resis-
tance
10 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 11
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13
Failure code [DXH3KA] (Lo clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lo clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to Lo clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

2) Connect T-adapter to connector ATC3 (male).
Resis-
tance
Resis-
tance
state harness
contact)
Max. 1 z
3
5 – 15 z
– (13) tance
14 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 15
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)1
Action code Failure code Lo clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Excessive current flows while output to Lo clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
3) Connect T-adapter to ATC3 (female).
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (6) – CN17 (female) Min. 1 Mz
2 tance
or contact between har- (1)
(6) – CN17 (female) (1) and wiring harness Resis-
Min. 1 Mz
from ATC3 (female) (13) – CN17 (female) tance
(2)
3
controller Resis-
tance
16 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 17
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Lo clutch ECMV is turned “OFF“, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
value in normal 2) Disconnect connectors ATC3 and CN17.
state 3) Connect T-adapter to ATC3 (female).
2
(1)
Turn starting switch OFF.
3 Resis-
controller Between ATC3 (female) (6) – (13) 5 – 15 z
tance
18 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 19
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
Failure code [DXH4KA] (1st clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 1st clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 1st clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (36) Resis-
2 Max. 1 z
(Disconnection or improper – CN6 (female) (1) tance
Max. 1 z
Defective transmission 2) Connect T-adapter to ATC3 (female).
3
controller Resis-
tance
22 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 23
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)1
Action code Failure code 1st clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows when output to 1st clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
2) Disconnect connectors to ATC3 and CN6.
and standard
Short circuit of harness 3) Connect T-adapter to connector ATC3 (female).
value in normal
state (Contact with ground circuit Between ground and wiring harness between Resis-
2 Min. 1 Mz
or contact between har- ATC3 (female) (36) – CN6 (female) (1) tance
Resis-
tance
3
controller Resis-
tance
24 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 25
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit
Action code Failure code 1st clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to 1st clutch ECMV is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(1)
3
controller Resis-
tance
26 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 27
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Failure code [DXH5KA] (2nd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 2nd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
state harness
contact)
Max. 1 z
3
controller Resis-
tance
30 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 31
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short cir-
cuit) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 2nd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2 between ATC3 (female) (5) – CN8 (female) Min. 1 Mz
(1)
nesses)
Resis-
tance
3
controller Resis-
tance
32 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 33
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit in power source line
Trouble
Contents of
trouble • When output to 2nd clutch ECMV is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(1)
3
controller Resis-
tance
34 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 35
36 HD465-7R, HD605-7R
HD465-7R, HD605-7R 37
Failure code [DXH6KA] (3rd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 3rd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 3rd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
and standard 2) Disconnect T-adapter connectors to ATC3 (female) and CN10
value in normal Disconnection in wiring (male).
state harness
contact)
Max. 1 z
3
controller Resis-
tance
38 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 39
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short cir-
cuit) 1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 3rd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
1 Defective 3rd clutch ECMV Between CN10(male) (1) – (2) 5 – 15 z
tance
Resis-
tance
(female) (1)
nesses)
Resis-
tance
3
controller Resis-
tance
40 HD465-7R, HD605-7R
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R
Low Low RH R OFF
HD465-7R, HD605-7R 41
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit
Action code Failure code 3rd clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to 3rd clutch ECMV is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
42 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 43
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45
Failure code [DXH7KA] (R clutch solenoid output circuit:

Disconnection) 1
Action code Failure code R clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to R clutch ECMV is ON.
Action of • The controller sets the gear in neutral.

Problem that
appears on • Machine can not move off in any gear speeds.
machine
after repair.

Resis-
tance
Resis-
tance
state harness
contact)
Max. 1 z
3
controller Resis-
tance
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)1

Action code Failure code R clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to R clutch ECMV is ON.

Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
3) Connect T-adapter to ATC3 (female).
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (25) – CN12 Min. 1 Mz
2 tance
or contact between har- (female) (1)
(25) – CN12 (female) (1) and wiring harness Resis-
Min. 1 Mz
from ATC3 (female) (23) – CN12 (female) tance
(2)
3
controller Resis-
tance
48 HD465-7R, HD605-7R
HD465-7R, HD605-7R 49
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to

power source line) 1
Action code Failure code R clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to R clutch ECMV is OFF, current flows to circuit.

Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
50 HD465-7R, HD605-7R
HD465-7R, HD605-7R 51
Failure code [DXHHKA] (4th clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 4th clutch solenoid output circuit: Disconnection
Trouble
E03 DXHHKA (Transmission controller system)
Contents of
trouble • Current does not flow when output to 4th clutch ECMV is ON.

Problem that
machine
after repair.

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (16) Resis-
2 Max. 1 z
(Disconnection or defective – CN14 (female) (1) tance
Max. 1 z
3
5 – 15 z
– (3) tance
52 HD465-7R, HD605-7R
HD465-7R, HD605-7R 53
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short

circuit) 1
Action code Failure code 4th clutch solenoid output circuit: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of
trouble • Abnormally excessive current flows while output to 4th clutch ECMV is ON.

Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
(female) (1)
nesses)
Resis-
tance
3
controller Resis-
tance
54 HD465-7R, HD605-7R
HD465-7R, HD605-7R 55
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit
Action code Failure code 4th clutch solenoid output circuit: Short circuit to power source line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of
trouble • When output to 4th clutch ECMV is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
56 HD465-7R, HD605-7R
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-7R, HD605-7R 57
58 HD465-7R, HD605-7R
HD465-7R, HD605-7R 59

© 2007 KOMATSU
All Rights Reserved
60 HD465-7R, HD605-7R
SEN02542-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Troubleshooting of electrical system
(E-mode)
Before troubleshooting of electric system ....................................................................................................... 3
E-1 Engine does not start ............................................................................................................................... 5
E-2 Automatic preheating does not operate ................................................................................................... 8
E-3 Machine monitor does not display all, when starting switch is turned ON.............................................. 12
E-4 Machine monitor does not operate when starting switch is OFF............................................................ 14
E-5 Alarm buzzer does not sound................................................................................................................. 16
section do not display properly. ............................................................................................................. 18
E-7 A selection of the display in character display section cannot be changed............................................ 19
E-8 Power mode selecting function does not operate properly .................................................................... 22
E-9 AISS function does not operate properly................................................................................................ 23
E-10 Seat belt caution lamp does not display properly................................................................................. 24
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly ................................................. 25
HD465-7R, HD605-7R 1
E-12 Night illumination (lighting) does not work properly .............................................................................. 28

E-13 Emergency steering does not operate.................................................................................................. 40
E-14 Hoist lever does not operate normally .................................................................................................. 46
2 HD465-7R, HD605-7R
Before troubleshooting of electric system 1

a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and slow-blow fuses to see if the power is supplied normally.
a When checking, see "Troubleshooting by failure code (General)", "Before carrying out troubleshooting
when failure code is displayed".
HD465-7R, HD605-7R 3

a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "Good"
or "No Good" about presumed causes.
1
• References for making judgement of "Good" or "No Good".
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wir-
ing harness has occurred.
• Grounding fault
2 A wiring harness that is not originally connected with a
grounding circuit is in contact with it.
• Failure due to short-circuiting
A wiring harness that is not originally connected with a
power source circuit (24 V) is in contact with it.
Possible causes Cause for presumed
and standard failure (The attached No. is <Points to remember in troubleshooting>
value in normal 3 for filing and reference 1) Connector denotation method and handling of T-adapters
state purpose only. It does not Insert or connect T-adapters in the following manner,
stand for any priority.) unless specifically owhterwise instructed.
• If there is no indication of "male" or "female" in the con-
nector No., pull off a connector and insert a T-adapter
into both sides of male and female
• If there is an indication of "male" and "female" in the
4 connector No., pull off a connector and insert a T-adapter
into only one side of "male" or "female".
2) Description sequence of pin No. and handling of circuit
tester leads
Connect the positive lead (+) and negative lead (-) for trou-
bleshooting in the following manner unless specifically
otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the
5
front or wiring harness.
• Connect the negative lead (-) to a pin No. marked at the
rear of wiring harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow ( ) : Roughly indicates the location in the machine where it is installed.
4 HD465-7R, HD605-7R
E-1 Engine does not start 1

Trouble Engine does not start.
Related • When failure code related to engine controller or transmission is present, troubleshooting the corre-
information sponding failure code first.

Gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective circuit breaker
FUA2 and FUB2 or defec- When circuit breaker FUA2, FUB2 is shut off, or fuse BT2 (19) –
2 tive fuse BT2 (19) – (20), (20), BT3 (13) – (14) and BT3 (21) – (22) is blown, it is highly pos-
BT3 (13) – (14) and BT3 (21) sible that a defective grounding has occurred in the circuit.
– (22)
2) Start engine and carry out troubleshooting.
3) Gearshift lever: Neutral
Defective engine starter
3 The problem is
relay (R01) Replace relay (R01) Defective relay
resolved.
with other relay
(5 terminals) The problem is not
Relay is normal
resolved.
Defective engine starting 2) Set gearshift lever in neutral and carry out troubleshooting.
4 relay (R01) coil, gearshift
lever or wiring Resistance 230 – 350
Between starting motor terminal B – ground
(Coil of R01) z
2) Disconnect connector D01 (female) and D08 (male).
Possible causes
5 Defective diode (D01), (D08) Between (1) – (2) Continuity None
and standard D01, D08 (male)
value in normal Between (2) – (1) Continuity Yes
state
• Troubleshooting in a diode range.
1) Turn starting switch OFF and carry out troubleshooting.
Defective alternator 2) Insert T-adapter in connector E02A.
6
(regulator) Between alternator terminal R (E01) –
Voltage Max. 12V
ground
1) Prepare with starting switch OFF.
7 Defective battery relay 2) Turn starting switch ON and carry out troubleshooting.
Between starting motor terminal B – ground Voltage 20 – 30 V
2) Disconnect battery ground cable, connector SF1, battery relay
and starting switch terminals.
Wiring harness between BT2 (19) – battery Resis-
Max. 1 z
relay (76) terminal B tance
harness Wiring harness between BT3 (13) – battery Resis-
Max. 1 z
8 (Disconnection or defective relay (77) terminal M tance
contact) Harness between battery (+) terminal – bat- Resis-
(Power supply circuits) Max. 1 z
tery relay (76) terminal B tance
Harness between BT2 (20) – starting switch Resis-
Max. 1 z
(terminal B) tance
Resis-
Harness between BT3 (14) – SF1 (male) (1) Max. 1 z
tance
HD465-7R, HD605-7R 5

Harness between starting switch (terminal
BR) – battery relay (61) terminal BR
Disconnection in wiring Continuity Continue
(Troubleshooting in the diode range from
harness starting switch (terminal BR) side)
8 (Disconnection or defective
Harness between battery relay (60) terminal Resis-
contact) Max. 1 z
(-) – frame ground (ER2) tance
(Power supply circuits)
Harness between battery relay (77) terminal Resis-
Max. 1 z
M – starting motor (terminal B) tance
2) Disconnect connectors R01, E02A, and starting switch termi-
nals.
Harness between starting switch (terminal Resis-
C) – R01 (female) (5) tance
harness
(Disconnection or defective Harness between R01 (female) (3) – E02B Resis-
9 Max. 1 z
contact) (female) (1) tance
(Related circuit after starting Harness between R01 (female) (3) – E02A Resis-
switch terminal C) Max. 1 z
(female) (1) tance
Harness between R01 (female) (1) – SF1 Resis-
Max. 1 z
(male) (4) tance
and standard Between R01 (female) (2) – ground (ER1) Max. 1 z
tance
value in normal
2) Disconnect connectors R01, E02A, and starting switch termi-
nals.
Hot short of wiring harness Between ground and wiring harness
10
(Contact with 24 V circuit) between alternator (terminal R) – E02A Voltage Max. 1V
(male) (2)
Between ground and wiring harnesses
between CJE3 (female) (1) – ATC1 (female) Voltage Max. 1V
(24), BRC1 (female) (15) – D01 (female) (2)
Defective starting switch 2) Disconnect starting switch terminals.
11 (Between terminals B – C or
BR) Starting switch unit (between B – C), Resis-
Max. 1 z
(between B – BR) tance
1) Turn starting switch ON and carry out troubleshooting.
Between starting motor (B terminal) –
Voltage 20 – 30 V
ground
12 Defective starting motor
2) Insert T-adapter in connector E02A.
Between E02A (1) – ground Voltage 20 – 30 V
Between E02B (1) – ground Voltage 20 – 30 V
6 HD465-7R, HD605-7R
HD465-7R, HD605-7R 7
E-2 Automatic preheating does not operate 1

Auto-preheater does not operate when starting switch is turned ON while engine coolant temperature
Trouble
is below -5 °C.
• Carry out following troubleshooting when failure neither of codes [CA2555] and [CA2556] are dis-
played.
Related
(If either of these failure codes is displayed, carry out troubleshooting for it first.)
information
• While engine coolant temperature is above -5 °C, auto-preheater does not operate.
• Engine coolant temperature can be checked with monitoring function (Code: 04104 (°C))

Defective circuit breaker When the circuit breaker is shut off or the fuse is blown, it is highly
1 FUA2, FUB2 and defective possible that a defective grounding has occurred in the circuit
fuse BT2 (20), BT4 (4) (troubleshooting cause 8).
Defective high current fuse Fuse is normal if continuity exists between inlet and outlet of high
2
(120A) (fuse is blown) current fuse (disconnect the inlet and outlet terminals).
1) Prepare with starting switch OFF, then carry out troubleshooting
Defect intake air heater without turning starting switch ON.
(Internal disconnection) Resis-
3 Between heater inlet terminal – ground Max. 1 z
(Internal resistance: tance
Max. 0.2 z) Resis-
Between heater (-) terminal – ground Max. 1 z
tance
1) Turn starting switch OFF and carry out troubleshooting.
2) Disconnect heater relay terminal.
Between heater relay coil side (-) terminal – Resis-
10 – 20 z
ground tance
2) Disconnect connector BT (input on heater relay primary side).
3) Prepare wire and connect battery relay terminal 75 to heater
Defective heater relay relay terminal E11B.
4 (Internal disconnection or 4) Connect battery ground cable.
defective contact) 5) Turn starting switch ON and carry out troubleshooting.
Possible causes (It does not turn ON 5 minites or more)
and standard Between heater relay terminal (E12B) –
value in normal Voltage 15 – 28 V
ground
state Between heater relay terminal (RLY) –
Voltage 15 – 28 V
ground
Between heater relay terminal (E11B) –
Voltage 15 – 28 V
ground
Defective auto preheater 2) Replace R37 with horn relay (R11).
relay (R37)
Turn horn ON. Horn sounds.
2) Disconnect connector E17B.
There is
Between (1) + – (2) - Continuity not
6 Defective diode (E17B) continuity
E17B (male)
There is
Between (1) - – (2) + Continuity
continuity
• Check in diode check mode.
Between starting switch terminal B – ground Voltage 15 – 28 V
Defective starting switch
Between starting switch terminal ACC –
7 (Defective contact between Voltage 15 – 28 V
ground
contact points B and ACC)
• If no problem is found by above diagnoses, starting switch is
defective.
8 HD465-7R, HD605-7R

2) Disconnect terminals of circuit breaker, starting switch, slow-
blow fuse, and heater relay.
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (RLY) – air heater inlet terminal tance
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (E12B) – high current fuse outlet terminal tance
Wiring harness between slow-blow fuse Resis-
Max. 1 z
inlet – battery relay terminal M (75). tance
Disconnection in wiring Wiring harness between battery relay termi- Resis-
Max. 1 z
harness nal M (75) – circuit breaker FUB2 terminal tance
8
(Disconnection or defective Wiring harness between circuit breaker
contact) Resis-
FUB2 terminal – fuse BT4 (3), (4) – R37 Max. 1 z
tance
(female) (5)
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal B (74) – circuit breaker FUA2 terminal tance
Wiring harness between circuit breaker
Resis-
FUA2 terminal – fuse BT2 (19), (20) – start- Max. 1 z
tance
ing switch terminal B
Wiring harness between starting switch ter-
Resis-
minal ACC-fuse BT3 (19), (20) – J2P Max. 1 z
tance
(female) (39)
and standard 2) Disconnect terminals of circuit breaker, slow-blow fuse, heater
value in normal relay, heater terminal, and starting switch.
state Between ground and wiring harness
Resis-
between heater relay terminal (RLY) – air Min. 1 Mz
tance
heater inlet terminal
Resis-
between heater relay terminal (E12B) – high Min. 1 Mz
tance
current fuse outlet terminal
Resis-
between slow-blow fuse inlet – battery relay Min. 1 Mz
tance
terminal M (75).
Resis-
Short circuit of harness between battery relay terminal M (75) – cir- Min. 1 Mz
9 tance
(Contact with ground circuit) cuit breaker FUB2 terminal (64)
Resis-
between circuit breaker FUB2 terminal – Min. 1 Mz
tance
fuse BT4 (3), (4) – R37 (female) (5)
Resis-
between battery relay terminal B (74) – cir- Min. 1 Mz
tance
cuit breaker FUA2 terminal
between circuit breaker FUA2 terminal – Resis-
Min. 1 Mz
fuse BT2 (19), (20) – starting switch terminal tance
B
Resis-
between starting switch terminal ACC – fuse Min. 1 Mz
tance
BT3 (19), (20) – J2P (female) (39)
HD465-7R, HD605-7R 9
10 HD465-7R, HD605-7R
HD465-7R, HD605-7R 11
E-3 Machine monitor does not display all, when starting switch is turned
ON 1
Trouble Lamps and gauges of machine monitor do not display all, when starting switch is turned ON.
Related
• When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information

Defective fuse BT2 (2), (20) When the fuse BT2 (2), (20) or (30) is blown or the circuit breaker
1 or (30) or defective circuit FUA2 is shut off, it is highly possible that a defective grounding has
breaker FUA2 occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female).
3) Disconnect fuse terminal of starting switch.
Max. 1 z
(7) – fuse BT2 (2) tance
Disconnection in wiring Wiring harness between BT2 (1) – starting Resis-
harness Max. 1 z
2 switch terminal ACC tance
contact) Wiring harness between BT2 (20) – starting Resis-
Max. 1 z
switch terminal B tance
Wiring harness between circuit breaker Resis-
Max. 1 z
FUA2 – fuse BT2 (19) tance
Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
Possible causes ER2 tance
value in normal 2) Disconnect connector DPC1 and terminals of fuse and starting
state switch.
Resis-
between DPC1 (female) (6), (7) – fuse BT2 Min. 1 Mz
tance
(2)
Short circuit of harness Resis-
3 between BT2 (1) – starting switch terminal Min. 1 Mz
ACC
Resis-
between fuse BT2 (20) – starting switch ter- Min. 1 Mz
tance
minal B
Resis-
between circuit breaker FUA2 – fuse BT2 Min. 1 Mz
tance
(19)
Defective machine 2) Insert T-adapter in connector DPC1.
monitor
Between DPC1 (6), (7) – (9), (10) Voltage 20 – 30 V
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13
E-4 Machine monitor does not operate when starting switch is OFF 1
Service meter and travel distance integrating meter, turn signal pilot lamp, and high beam pilot lamp
Trouble
do not flash, if the switches are operated with starting switch OFF.
Related
information

Defective fuse BT2 (30) or When the fuse BT2 (30) is blown or the circuit breaker FUA2 is
1 defective circuit breaker shut off, it is highly possible that a defective grounding has
FUA2 occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female).
3) Disconnect terminals of BT2 (30) and FUA2.
Disconnection in wiring Wiring harness between DPC1 (female) (4), Resis-
harness Max. 1 z
2 (5) – fuse BT2 (30) tance
contact) Wiring harness between circuit breaker Resis-
Max. 1 z
FUA2 – fuse BT2 (29) tance
Possible causes Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
and standard ER2 tance
value in normal 1) Disconnect battery ground cable.
state 2) Connect T-adapter to connector DPC1 (female).
3) Disconnect terminals of BT2 (30) and FUA2.
3 between DPC1 (female) (4), (5) – fuse BT2 Min. 1 Mz
(30)
Resis-
between circuit breaker FUA2 – fuse BT2 Min. 1 Mz
tance
(29)
2) Insert T-adapter in connector DPC1.
4 Defective machine monitor 3) Turn starting switch ON.
Between DPC1 (4), (5) – (9), (10) Voltage 20 – 30 V
14 HD465-7R, HD605-7R
HD465-7R, HD605-7R 15
E-5 Alarm buzzer does not sound 1

The alarm buzzer does not sound when the starting switch is ON, emergency stop item lamps are ON,
Trouble
and centralized warning lamp is ON.
Related
information

When the fuse BT2 (16) is blown, it is highly possible that a defective
1 Defective fuse BT2 (16)
grounding has occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female) and BZ2
(female).
Disconnection in wiring Wiring harness between DPC1 (female) Resis-
harness Max. 1 z
2 (13) – BZ2 (female) (2) tance
contact) Wiring harness between BZ2 (female) (1) – Resis-
Max. 1 z
fuse BT2 (16) tance
Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
ER2 tance
Possible causes 2) Disconnect connector DPC1 and BZ2.
and standard 3) Connect T-adapter to DPC1 (female).
state 3 Between ground and wiring harness between Resis-
(Contact with ground circuit) Min. 1 Mz
DPC1 (female) (13) – BZ2 (female) (2) tance
Between ground and wiring harness Resis-
Min. 1 Mz
between BZ2 (female) (1) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC1.
Measurement
DPC1 Voltage
conditions
When the buzzer
20 – 30 V
does not sound
Between (13) – (9), (10)
When the buzzer
Max. 1V
sounds
* Set up the conditions to actuate the buzzer for the measurement.
16 HD465-7R, HD605-7R
HD465-7R, HD605-7R 17

section do not display properly 1
Trouble Gauges, lamps or character display section are malfunctioning
Related
information

Defective sensors or Troubleshooting corresponding sensors or switches by the failure
Possible causes 1
switches code.
and standard
value in normal Defective CAN communica-
2 Troubleshooting by the communication related failure code
state tion circuit
If no problem is found in above 1 and 2, machine monitor is defec-
tive (since this is an internal defect, it cannot be diagnosed).
18 HD465-7R, HD605-7R
E-7 A selection of the display in character display section cannot be

changed 1
Trouble (1) When the mode selector switch 1 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH1 (male).
Resis-
CH1 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [U]. Max. 1 z
selector switch 1 (CH1)
Between (3) – (2)
Switch is in the neutral. Min. 1 Mz
Press the switch [t]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH1
(female).
Disconnection in wiring Wiring harness between CH1 (female) (1) – Resis-
harness Max. 1 z
3 DPC2A (female) (14) tance
contact) Wiring harness between CH1 (female) (2) – Resis-
Max. 1 z
DPC2A (female) (8) tance
Possible causes
and standard Wiring harness between CH1 (female) (3) – Resis-
Max. 1 z
value in normal fuse BT2 (30) tance
2) Disconnect connectors DPC2A and CH1.
3) Connect T-adapter to DPC2A.
Resis-
between CH1 (female) (1) – DPC2A Min. 1 Mz
Short circuit of harness tance
4 (female) (14)
Resis-
tance
(female) (8)
Min. 1 Mz
between CH1 (female) (3) – fuse BT2 (30) tance
2) Insert T-adapter in connector DPC2A.
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [U]. 20 – 30 V
Between (8) –
ground Switch is in the neutral. Max. 1V
Between (14) – Press the switch [t]. 20 – 30 V
HD465-7R, HD605-7R 19
Trouble (2) When the mode selector switch 2 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH2 (male).
Resis-
CH2 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [>]. Max. 1 z
selector switch 2 (CH2)
Between (3) – (2)
Press the switch [<]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH2
(female).
Disconnection in wiring Wiring harness between CH2 (female) (1) – Resis-
harness Max. 1 z
3 DPC2A (female) (15) tance
contact) Harness between CH2 (female) (2) – Resis-
Max. 1 z
DPC2A (female) (6) tance
Possible causes
and standard Wiring harness between CH2 (female) (3) – Resis-
Max. 1 z
value in normal fuse BT2 (16) tance
2) Disconnect connectors DPC2A and CH2.
Resis-
Short circuit of harness tance
4 (female) (15)
Resis-
tance
(female) (6)
Min. 1 Mz
between CH2 (female) (3) – fuse BT2 (16) tance
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [>]. 20 – 30 V
Between (6) –
Between (15) – Press the switch [<]. 20 – 30 V
20 HD465-7R, HD605-7R
HD465-7R, HD605-7R 21
E-8 Power mode selecting function does not operate properly 1

When power mode selector function does not operate properly, even if the power mode selector
Trouble
switch is operated.
Related
information

2) Connect T-adapter to connector PWM (male).
Defective power mode Resis-
2 PWM (male) Operation of switch (switch unit)
selector switch tance
Switch: down Max. 1 z
Between (1) – (3)
Switch: up Min. 1 Mz
2) Connect T-adapter to connectors DPC2A (female) and PWM
harness
3 Wiring harness between DPC2A (female) Resis-
Possible causes (13) – PWM (female) (3) tance
contact)
and standard Wiring harness between PWM (female) (1) Resis-
– fuse BT2 (16) tance
state
2) Disconnect connectors DPC2A and PWM.
Short circuit of harness Between ground and wiring harness
4 Resis-
(Contact with ground circuit) between DPC2A (female) (13) – PWM Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between PWM (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (13) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
22 HD465-7R, HD605-7R
E-9 AISS function does not operate properly 1

Trouble When AISS function does not operate properly, even if the AISS LOW switch is operated.
Related • When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information • If the brake pilot lamp is not normally turned ON or OFF, carry out troubleshooting and repair first.

2) Connect T-adapter to connector AISS (male).
Resis-
2 Defective AISS switch AISS (male) Operation of switch (switch unit)
tance
Switch: up Min. 1 Mz
Between (1) – (3)
Switch: down Max. 1 z
2) Connect T-adapter to connectors DPC2A (female) and AISS
harness
3 Wiring harness between DPC2A (female) Resis-
Possible causes (2) – AISS (female) (3) tance
contact)
and standard Wiring harness between AISS (female) (1) – Resis-
fuse BT2 (16) tance
state
2) Disconnect connectors DPC2A and AISS.
4 Resis-
(Contact with ground circuit) between DPC2A (female) (2) – AISS Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between AISS (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (2) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
HD465-7R, HD605-7R 23
E-10 Seat belt caution lamp does not display properly 1

The lamp lights up even if the seat belt is fastened, or the lamp does not light up even if the seat belt is
Trouble
not fastened.
Related
information

2) Connect T-adapter to connector SBS (male).
3) Check switch unit.
2 Defective seat belt switch Resis-
SBS Seat belt
tance
Fastened Max. 1 z
Between (1) – (2)
Unfastened Min. 1 Mz
2) Connect T-adapter to connectors DPC2B (female) and SBS
harness
3 Wiring harness between DPC2B (female) Resis-
Possible causes (Disconnection or defective Max. 1 z
(11) – SBS (female) (2) tance
and standard contact)
value in normal Wiring harness between SBS (female) (2) – Resis-
Max. 1 z
state fuse BT2 (16) tance
2) Disconnect connectors DPC2B and SBS.
4 Resis-
(Contact with ground circuit) between DPC2B (female) (11) – SBS Min. 1 Mz
tance
(female) (2)
Min. 1 Mz
between SBS (female) (2) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC2B.
5 Defective machine monitor DPC2B Seat belt Voltage
Between (11) – Fastened 20 – 30 V
ground Unfastened Max. 1V
24 HD465-7R, HD605-7R
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly1
Trouble Turn signal lamp or turning lamp (hazard lamp) do not flash.
Explanation of circuit
1) If 24 V is input to pin (3), the flasher keeps outputting signals of 24 V and 0 V from pin (4) repeat-
edly.
2) The input of 24 V to flasher pin (3) is changed by relay (R17). It is supplied through BT1 for turn sig-
nal lamp and through BT2 for hazard lamp.
3) The flasher output is supplied constantly (regardless of the position of the switch) through connector
Related
(CM) to pin (6) of the turn switch and to pins (1) and (3) of hazard relay (R16).
information
4) When the turn switch is turned ON, the flashing signal is input to pin (6) of connector (CM) and the
turn switch sends that signal to the left side (pin (7)) or right side (pin (8)).
5) If the hazard switch is pressed, pins (1) and (3) of relay (HAZ) are connected and hazard relays 1
(R16) and 2 (R17) are turned ON. Hazard relay 2 (R17) changes the power supply from BT1 to
BT2 and hazard relay 1 (R16) connects the flashing signal from the flasher to both of the right side
and left side.

When the fuse BT1 (4) or BT2 (24) is blown, it is highly possible
Defective fuse BT1 (4) or
1 that a defective grounding has occurred in the circuit (troubleshoot-
BT2 (24)
ing cause 7).
Since the lamp can be suspected to be defective, visually check it
2 Defective lamp
or replace it with known good lamp to make a judgement.
2) Insert T-adapter in connector FLS.
3 Defective turn signal lamp
FLS Voltage
Between (3) – ground 20 – 30 V
Between (4) – ground 20 – 30 V and 0 V repeatedly
2) Connect T-adapter to connector FLS (male).
3) Check switch unit.
Resis-
CM (male) Turn switch (lever)
4 Defective turn switch tance
Turned to the left Max. 1 z
Between (6) – (7)
Turned to the right Min. 1 Mz
Possible causes Turned to the right Max. 1 z
and standard Between (6) – (8)
Turned to the left Min. 1 Mz
value in normal
When the relay can be suspected to be defective, replace it with
state
another relay to make a judgement.
5 Defective relay • As for the relay R16 (6 terminals): Replace with the relay R21,
R40 or R05, etc.
• Relay R17 (5-pole): Replace with relay R11, R30, R31, etc.
2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Wiring harness between BT1 (4) – R17 Resis-
Max. 1 z
(female) (6) tance
Disconnection in wiring Wiring harness between BT2 (24) – R17 Resis-
Max. 1 z
harness (female) (5) – HAZ (female) (1) tance
6
(Disconnection or defective Wiring harness between HAZ (male) (3) – Resis-
Max. 1 z
contact) R17 (female) (1) – R16 (female) (5) tance
Max. 1 z
FLS (female) (3) tance
Max. 1 z
CM (female) (7) – DPC2A (female) (7) tance
Max. 1 z
CM (female) (8) – DPC2A (female) (16) tance
HD465-7R, HD605-7R 25

Wiring harness between R16 (female) (1), Resis-
Max. 1 z
(3) – FLS (female) (4) – CM (female) (6) tance
Wiring harness between CM (female) (7) – Resis-
Max. 1 z
PR03 (female) (3) (left front) tance
Max. 1 z
B03 (female) (1) (left rear) tance
Max. 1 z
PL03 (female) (3) (right front) tance
Max. 1 z
B02 (female) (1) (right rear) tance
Between PR03 (female) (2) – ground (left Resis-
Max. 1 z
Disconnection in wiring front) tance
harness Between PL03 (female) (2) – ground (right Resis-
6 Max. 1 z
(Disconnection or defective front) tance
contact) Between B03 (female) (6) – CJR (3), (6) – Resis-
Max. 1 z
ground (B10) (right rear) tance
Between B02 (female) (6) – CJR (2), (6) – Resis-
Max. 1 z
ground (B10) (left rear) tance
Resis-
Between HAZ (male) (4) – ground (ER1) Max. 1 z
tance
Resis-
Between R17 (female) (2) – ground (ER1) Max. 1 z
tance
Resis-
tance
Resis-
Between FLS (female) (1) – ground (ER1) Max. 1 z
Possible causes tance
value in normal 2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
state PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Min. 1 Mz
between BT1 (4) – R17 (female) (6) tance
Resis-
between BT2 (24) – R17 (female) (5) – HAZ Min. 1 Mz
tance
(male) (1)
Resis-
between HAZ (male) (3) – R17 (female) (1) Min. 1 Mz
tance
– R16 (female) (5)
Resis-
between R17 (female) (3) – FLS (female) Min. 1 Mz
tance
Short circuit of harness (3)
7
Resis-
between R16 (female) (4) – CM (female) (7) Min. 1 Mz
tance
– DPC2A (female) (7)
Resis-
between R16 (female) (2) – CM (female) (8) Min. 1 Mz
tance
– DPC2A (female) (16)
Resis-
between R16 (female) (1), (3) – FLS Min. 1 Mz
tance
(female) (4) – CM (female) (6)
Resis-
between CM (female) (7) – PR03 (female) Min. 1 Mz
tance
(3) (right front)
Resis-
between CM (female) (7) – B03 (female) (1) Min. 1 Mz
tance
(left front)
26 HD465-7R, HD605-7R

between CM (female) (8) – PL03 (female) Min. 1 Mz
and standard tance
Short circuit of harness (3) (right front)
value in normal 7
state Resis-
between CM (female) (8) – B02 (female) (1) Min. 1 Mz
tance
(right rear)
HD465-7R, HD605-7R 27
E-12 Night illumination (lighting) does not work properly 1

Trouble (1) Small lamps (clearance lamp, tail lamp), night illumination and head lamp do not light up at all.
Explanation of relay circuit
1) The 24V power source from fuse BT1 pin (2) is supplied to light switch pin (4), passing switch pin
(1), and small lamp relay (R46) pin (5).
2) If the light switch is set in the small position, small lamp relay (R46) is turned ON. The 24V power
supplied to R46 pin (5) is output through R46 pin (3). Then, the 24V power is supplied again
through fuse BT1 pin (17) to each small lamp.
3) If the light switch is set in the head (low) position, head lamp low relay (R31) is turned ON and 24V
power supplied through fuse BT1 pin (6) is output through R31 pin (3). Then, the 24V power is sup-
Related
plied again through fuse BT1 pin (9) to each low lamp.
information
4) If the light switch is set in the head (low) and high beam position, DPC1 pin (14) is grounded and
headlamp high relay (R30) is turned ON. The 24V power supplied through fuse BT1 pin (8) is out-
put through R30 pin (3). Then, the 24V power is supplied again through fuse BT1 pin (11) to each
high lamp.
5) If passing switch is turned ON, headlamp high pass relay (R29) is turned ON. The 24V power sup-
plied through fuse BT1 pin (8) is output through R29 pin (3) and connected to R30 pin (3) and then
supplied through the high beam circuit. (The 24V power is supplied again through fuse BT1 pin (11)
to each high lamp.)

Defective circuit breaker If fuse BT1 (2) or (17) is broken, circuit probably has ground fault.
1
FUB1 or fuse BT1 (2) or (17) (Check by Cause 4.)
2) Connect T-adapter to connector CM (male).
CM (male) Lamp switch Resistance
2 Defective lamp switch Between (1) – (2) Max. 1 z
1st detent
Between (1) – (3) Min. 1 Mz
2nd detent
Defective small lamp relay 2) Replace R46 with horn relay (R11).
(R46)
2) Connect T-adapter to connector CM (female)
Possible causes
3) Disconnect R46, J02 and J03.
and standard
value in normal Wiring harness between circuit breaker Resis-
Disconnection in wiring har- Max. 1 z
state FUB1 (63) – CM (female) (1), (4) or R46 (5) tance
ness
4 (Disconnection in wiring or Resis-
Between CM (female) (2) – R46 (female) (1) Max. 1 z
defective contact in connec- tance
tor)
Resis-
Between R46 (female) (2) – ground ER1 Max. 1 z
tance
Between R46 (female) (3), J03 (28) – J02 Resis-
Max. 1 z
(3) tance
2) Disconnect connectors CM, R46, DPC2B, LS, RP, LP1, B01 and
B02.
3) Prepare and carry out troubleshooting with starting switch kept
OFF.
Ground fault in wiring har-
5 ness Wiring harness between BT1 (2) – R46 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (5) tance
Min. 1 Mz
R46 (female) (1) tance
Min. 1 Mz
BT1 (17) – each lamp tance
28 HD465-7R, HD605-7R
HD465-7R, HD605-7R 29
Small lamps (clearance lamp and tail lamp) or night illumination do not light up at the "first detent"
Trouble (2)
position of the lamp switch.
Related • When the head lamps light up.
information a See circuit diagram (1).

2) Connect T-adapter to connector CM (female).
1 Defective lamp switch
Between (1) – (2) 1st detent Max. 1 z
2) Disconnect connectors CM, R46, and J02 and terminals of fuse.
Possible causes Wiring harness between CM (female) (2) – Resis-

Max. 1 z
Disconnection in wiring har- R46 (female) (1) tance
and standard
value in normal ness Wiring harness between CM (female) (1), Resis-
2 Max. 1 z
state (Disconnection or defective (4) – R46 (female) (5) (branch point) tance
contact) Wiring harness between R46 (female) (3) –
Resis-
BT1 (17) – (18) – J02 (female) (3) (to branch Max. 1 z
tance
point)
Resis-
tance
Defective small lamp relay 2) Replace R46 with horn relay (R11).
(R46)
Trouble (3) Left small lamp (clearance lamp and tail lamp) does not "left" light up.
Related • Carry out following troubleshooting when right small lamp and headlamps light up.

When the lamp (bulb) can be suspected to be defective, judge by
1 Defective lamp (bulb)
visual check or replacing the lamp bulb.
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02, CJB, and PL03.
Disconnection in wiring Wiring harness between J02 (male) (3) – Resis-
harness Max. 1 z
2 CJB (female) (1) tance
Possible causes contact) Wiring harness between CJB (female) (6) – Resis-
Max. 1 z
and standard PL03 (female) (1) tance
value in normal Wiring harness between PL03 (female) (2) – Resis-
state Max. 1 z
ground (PL07) tance
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02 (male).
Short circuit of harness Between ground and wiring harness Resis-
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (6) – PL03 (female) Min. 1 Mz
tance
(1)
30 HD465-7R, HD605-7R
Trouble (4) Right small lamp (clearance lamp) does not "right" light up.
Related • Carry out following troubleshooting when left small lamp and headlamps light up.

2) Disconnect connectors J02, CJB, and PR03.
Disconnection in wiring Wiring harness between J02 (male) (3) – Resis-
Max. 1 z
harness CJB (female) (1) tance
2
(Disconnection or defective Wiring harness between CJB (female) (2) – Resis-
Possible causes contact) Max. 1 z
PR03 (female) (1) tance
and standard
value in normal Wiring harness between PR03 (female) (2) Resis-
Max. 1 z
state – ground (PR07) tance
2) Disconnect connectors J02, CJB, and PR03.
3) Connect T-adapter to J02 (male).
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (2) – PR03 (female) Min. 1 Mz
tance
(1)
Trouble (5) Left small lamp (tail lamp) does not "left" light up.
Related • Carry out following troubleshooting when right tail lamp and headlamps light up.

2) Disconnect connectors J02, CJV, and B02.
3) Connect T-adapter to J02, CJV, and B02.
Disconnection in wiring Wiring harness between J02 (branched Resis-
harness Max. 1 z
2 point) (female) (3) – CJV (female) (4) tance
contact) Wiring harness between CJV (female) (5) – Resis-
B02 (female) (5) tance
and standard
value in normal Wiring harness between B02 (female) (6) – Resis-
Max. 1 z
state ground (B10) tance
3) Connect T-adapter to J02 (female).
3 between J02 (male) (branch point) (3) – Min. 1 Mz
CJV (female) (4)
Resis-
between CJV (female) (5) – B02 (female) Min. 1 Mz
tance
(5)
HD465-7R, HD605-7R 31
Trouble (6) Right small lamp (clearance lamp) does not "right" light up.
Related
• Carry out following troubleshooting when left tail lamp and headlamps light up.
information

3) Connect T-adapter to J02, CJV, and B03.
Disconnection in wiring Wiring harness between J02 (female) Resis-
harness Max. 1 z
2 (branch point) (3) – CJV (female) (4) tance
contact) Wiring harness between CJV (female) (3) – Resis-
B03 (female) (5) tance
and standard
value in normal Wiring harness between B03(female) (6) – Resis-
Max. 1 z
state ground (B10) tance
3) Connect T-adapter to J02 (female).
3 between J02 (male) (branched point) (3) – Min. 1 Mz
CJV (female) (4)
Resis-
between CJV (female) (3) – B03 (female) Min. 1 Mz
tance
(5)
32 HD465-7R, HD605-7R
HD465-7R, HD605-7R 33
Trouble (7) Head lamps "Lo beam" do not light up.

Related
• When the lamps light up in the Hi beam side.
information

When the fuse BT1 (6), (9) – (10) is blown, it is highly possible that
Defective fuse BT1(6), (9) –
1 a defective grounding has occurred in the circuit (troubleshooting
(10)
cause 5).
Defective headlamp low 2) Replace R31 with horn relay.
relay (R31)
2) Disconnect connectors PR01, PL01, CJA, R31.
Wiring harness between PR01 (female) (1) Resis-
Max. 1 z
– CJA (female) (5) (right side) tance
Wiring harness between PL01 (female) (1) – Resis-
Max. 1 z
CJA (female) (6) (left side) tance
Disconnection in wiring Wiring harness between CJA (female) (4) – Resis-
harness Max. 1 z
4 fuse BT1 (10) tance
contact) Wiring harness between fuse BT1 (9) – R31 Resis-
Max. 1 z
(female) (3) tance
Possible causes
and standard Wiring harness between CM (female) (3) – Resis-
Max. 1 z
value in normal R31 (female) (1) tance
state Wiring harness between R31 (female) (5) – Resis-
Max. 1 z
BT1(6) tance
Between R31 (female) (2) – JCA(5), (16) – Resis-
Max. 1 z
ground (ER1) tance
2) Disconnect connectors PR01, PL01, CJA, R31, and CM and ter-
minals of fuse.
Resis-
between PR01 (female) (1) – CJA (female) Min. 1 Mz
tance
(5) (right side)
Resis-
Short circuit of harness between PL01 (female) (1) – CJA (female) Min. 1 Mz
5 tance
(Contact with ground circuit) (6) (left side)
Min. 1 Mz
between CJA (female) (4) – fuse BT1 (10) tance
Min. 1 Mz
between fuse BT1 (9) – R31 (female) (3) tance
Min. 1 Mz
between CM (female) (3) – R31 (female) (1) tance
Min. 1 Mz
between R31 (female) (5) – BT1 (6) tance
34 HD465-7R, HD605-7R
HD465-7R, HD605-7R 35
Trouble (8) Head lamps "Hi beam" do not light up.

Related • When the lamps light up in the Lo beam side.

When the fuse BT1 (8), (11) – (12) is blown, it is highly possible
Defective fuse BT1 (8), (11) –
1 that a defective grounding has occurred in the circuit (troubleshoot-
(12)
ing cause 4).
2) Disconnect connectors PR02, PL02, DPC1, and CM and termi-
nals of fuse.
Wiring harness between PR02 (female) (1) Resis-
Max. 1 z
– CJA (female) (2) (right side) tance
Wiring harness between PL02 (female) (1) – Resis-
Max. 1 z
CJA (female) (6) (left side) tance
harness Wiring harness between CJA (female) (1) – Resis-
3 Max. 1 z
(Disconnection or defective fuse BT1 (12) tance
contact) Wiring harness between fuse BT1 (11) – Resis-
Max. 1 z
Max. 1 z
between R30 (female) (1) – CM (female) (3) tance
Wiring harness between DPC1 (female) Resis-
Max. 1 z
(14) – R30 (female) (2) *1 tance
Wiring harness between BT1 (8) (female) Resis-
Max. 1 z
Possible causes (1) – R30 (female) (5) tance
and standard
value in normal
2) Disconnect connectors PR02, PL02, DPC1, and CM and termi-
state
nals of fuse.
Resis-
between PR02 (female) (1) – CJA (female) Min. 1 Mz
tance
(2) (right side)
Resis-
between PL02 (female) (1) – CJA (female) Min. 1 Mz
tance
(6) (left side)
4 Min. 1 Mz
(Contact with ground circuit) between CJA (female) (1) – fuse BT1 (12) tance
Min. 1 Mz
between fuse BT1 (11) – R30 (female) (3) tance
Min. 1 Mz
CM (female) (3) tance
Resis-
between DPC1 (female) (14) – R30 (female) Min. 1 Mz
tance
(2) *1
Resis-
between BT1 (8) (female) (1) – R30 Min. 1 Mz
tance
(female) (5)
Defective headlamp high 2) Replace R30 with horn relay (R11).
relay (R30) *1
*1: Passing lamp lights up, even if head lamp "Hi beam" do not right up.
36 HD465-7R, HD605-7R
Trouble (9) Headlamp "low beam" and "high beam" do not light up.
Related • Carry out following troubleshooting when small lamps light up.

1 Defective lamp switch
Between (1) – (3) Turn to 2nd detent. Max. 1 z

Disconnection in wiring 2) Disconnect connectors R31, and CM and terminals.
and standard harness
value in normal 2 3) Connect T-adapter to connector of circuit to be measured.
state contact) Wiring harness between CM (female) (3) – Resis-
Max. 1 z
2) Disconnect connectors R31, and CM and terminals.
Short circuit of harness 3) Connect T-adapter to connector of circuit to be measured.
3
Min. 1 Mz
between CM (female) (3) – R31 (female) (1) tance
Trouble (10) Passing lamp does not light up.

Related • When head lamps light up properly. (High beam lights up)

1 Defective passing switch CM (male) Passing switch Resistance
Operated Max. 1 z
Between (4) – (5)
Not operated Min. 1 Mz
2) Disconnect connectors CM, R29, and DPC2A (female).
3) Connect T-adapter to CM, R29, and DPC2A (female).
Possible causes
and standard Wiring harness between CM (female) (5) – Resis-
value in normal R29 (female) (1) tance
harness
state 2 Wiring harness between R29 (female) (5) – Resis-
R30 (female) (5) (up to branch point) tance
contact)
Wiring harness between DPC2A (female) Resis-
Max. 1 z
(4) – CM (female) (5) (up to branch point) tance
Resis-
tance
Defective headlamp high 2) Replace R29 with horn relay (R11).
(pass) relay (R29)
HD465-7R, HD605-7R 37
Trouble (11) The brightness of the night illumination does not change, even if the rheostat is operated.
Related
information

2) Connect T-adapter to connector LS (male).
LS Rheostat Voltage
1 Defective rheostat Between (1) –
Neutral 20 – 30 V
ground
Between (2) – Left end 6 – 12 V
ground Right end 18 – 27 V
and standard 2) Connect T-adapter to connectors LS (female) and DPC2B
state harness
2 Wiring harness between LS (female) (2) – Resis-
DPC2B (female) (12) tance
contact)
Resis-
Between LS (female) (3) – ground (ER1) Max. 1 z
tance
2) Disconnect connectors LS and DPC2B.
Short circuit of harness 3) Connect T-adapter to LS (female).
3
Resis-
between LS (female) (2) – DPC2B (female) Min. 1 Mz
tance
(12)
38 HD465-7R, HD605-7R
HD465-7R, HD605-7R 39
E-13 Emergency steering does not operate 1

When steering pump stops, machine cannot be steered manually (emergency steering switch does
Trouble (1)
not work).
a See Operation and Maintenance Manual, Operation volume, "Operating procedure", Testing and
Related
adjusting before starting engine", "Testing emergency steering" and "Testing automatic emergency
information
steering".

Defective fuse EMPR, BT2 If fuse EMPR, BT2 (26) is blown, it is highly possible that a defec-
1
(26) tive harness grounding has occurred in the circuit.
2) Disconnect switch terminal and check switch unit.
Defective manual switch Manual switch Manual switch
2 Resistance
(internal defective contact) terminal operation
Between ST1 – ST2 Switch (pressed) Max. 1 z
(Switch unit) Switch (not pressed) Min. 1 Mz
Resis-
Between relay terminal (55) – ground Max. 1 z
tance
1) Start engine.
Defective emergency 2) Turn parking brake ON.
3
steering relay 3) Turn emergency steering switch ON.
1) Between relay terminal (72) – ground Voltage 20 – 30 V
1) Start engine.
2) Turn parking brake ON.
3) Turn emergency steering switch ON.
Possible causes Between motor terminal M and ground Voltage 20 – 30 V
Defective emergency
and standard 4 1) Turn starting switch OFF.
steering motor
value in normal Resis-
state Between motor terminal E and ground Max. 1 z
tance
• If no problem is found in above diagnoses, the steering motor is
defective.
Wiring harness between battery (+) (BT-2B) Resis-
Max. 1 z
– emergency steering relay (54) tance
Disconnection in wiring Wiring harness between relay terminal (71) Resis-
Max. 1 z
harness – motor terminal M tance
5
(Disconnection or defective Wiring harness between motor terminal E – Resis-
contact) Max. 1 z
ground tance
Wiring harness between relay terminal (53) Resis-
Max. 1 z
– ground tance
Wiring harness between relay terminal (70) Resis-
Max. 1 z
– battery (+) tance
1) Disconnect battery ground cable and battery (+) cable.
Short circuit (ground fault) of
Wiring harness between battery (+) (BT-2B) Resis-
6 harness Min. 1 Mz
– emergency steering relay (54) tance
Resis-
between relay terminal (71) – motor terminal Min. 1 Mz
tance
M
40 HD465-7R, HD605-7R
HD465-7R, HD605-7R 41
Trouble (2) Automatic emergency steering does not operate.

a See Operation and Maintenance Manual, Operation volume, "Operating procedure", Testing and
adjusting before starting engine", "Testing emergency steering" and "Testing automatic emergency
steering".
• Explanation of auto emergency steering circuit
1) When the parking brake is released, the parking brake switch is turned ON and a voltage (about 24
V) is generated at pin PSWR (2) (The power is supplied through fuse BT3 (16).)
Related 2) If the oil flow in the steering unit is lost and the steering pressure switch is turned ON, a voltage is
information generated at pin H01 (A).
3) The emergency steering timer operates and a voltage is generated at emergency steering timer
output pin (5).
a After the above operation, the steering circuit operates as in the manual operation (emergency
steering switch).
4) The emergency steering relay is turned ON and the emergency steering motor operates.
a For defects of the emergency steering relay and emergency steering motor, see Trouble (1).

2) Connect T-adapter to PSWR (male)
Defective parking brake
2 switch Resis-
PSWR (male) Parking brake operations
(internal defective contact) tance
Released (CLOSE) Max. 1 z
Between (1) – (2)
Operated (OPEN) Min. 1 Mz
2) Connect T-adapter to H01 (male)
Defective emergency steer-
3 ing oil pressure switch Resis-
H01 (male) Steering pump
(Internal contact) tance
Operated (OPEN) Min. 1 Mz
Between (A) – (C)
Stopped (CLOSE) Max. 1 z
Possible causes
and standard Resis-
Between EM (female) (1) – ground Max. 1 z
Defective emergency
4 2) Insert T-adapter in connector EM.
steering timer
3) Turn parking brake ON. (Turn line to EM (3) OFF)
4) Check by supplying 24 V to EM (3).
a Check within 90 seconds.
Between EM (female) (5) – ground Voltage 20 – 30 V
2) Disconnect connectors PSWR, CJN, EM, and BT3 (16).
Wiring harness between fuse BT-3 (16) – Resis-
Max. 1 z
Disconnection in wiring Wiring harness between PSWR (female) (2) Resis-
harness Max. 1 z
5 – CJN (female) (4) tance
contact) Wiring harness between CJN (female) (3) – Resis-
Max. 1 z
H01 (female) (C) tance
Wiring harness between H01 (female) (A) – Resis-
Max. 1 z
EM (female) (3) tance
Wiring harness between EM (female) (5) – Resis-
Max. 1 z
relay terminal (54) tance
42 HD465-7R, HD605-7R

2) Disconnect connectors PSWR, CJN, EM, and BT3 (16).
Resis-
between fuse BT-3 (16) – PSWR (female) Min. 1 Mz
tance
(1)
Possible causes Between ground and wiring harness
Resis-
and standard Short circuit (ground fault) of between PSWR (female) (2) – CJN (female) Min. 1 Mz
tance
value in normal 6 harness (4)
Resis-
between CJN (female) (3) – H01 (female) Min. 1 Mz
tance
(C)
Min. 1 Mz
between H01 (female) (A) – EM (female) (3) tance
Resis-
between EM (female) (5) – relay terminal Min. 1 Mz
tance
(54)
a The 5 factors in causing the trouble that "the emergency steering operates by itself (while the switch is
turned OFF)" are as follows. (Factors 4) and 5) can cause this trouble only when they occur simulta-
neously.)
1) The emergency steering relay is kept turned ON for 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 normally.)
3) The wiring of the emergency steering relay on the M side comes in contact with that on the B side.
(Open the battery box and check the wiring.)
4) Parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.)
5) Steering flow switch is stuck. (Replace steering flow switch.)
HD465-7R, HD605-7R 43
44 HD465-7R, HD605-7R
HD465-7R, HD605-7R 45
E-14 Hoist lever does not operate normally 1

Hoist lever does not operate normally.
Trouble (1) Hoist lever is not fixed at RAISE position.
(2) Hoist lever raise fixing device (detent) is not reset before body raising position.
• Failure code [DW72KZ] checks kick-out solenoid and [DK54KX] checks body positioner sensor.
Accordingly, if these codes are not displayed, it is judged that there is not breakage in solenoid coil
or disconnection/short circuit in sensor and wiring is normal.
Related • If detent is not reset, hoist lever kick-out is judge to be normal (solenoid is turned ON and OFF nor-
information mally). It should be judged that signal from body positioner sensor is not sent to controller normally.
If body is not hoisted at all, see failure codes [DK52KX] and [DK53LX] (Troubleshooting for hoist
lever potentiometer sensor).
• If kick-out solenoid is defective, replace hoist lever.

1) Turn starting switch OFF and insert T-adapter in LK0.
2) Start engine.
1 Defective hoist lever kick-out 3) Set hoist lever in RAISE position and check.
LK0 Voltage
Between (1) – (2) 20 – 30 V
Possible causes
and standard 1) Turn starting switch OFF and insert T-adapter in BRC1 (or in
value in normal connector on route to body positioner sensor).
state Defective body positioner 2) Start engine.
2 3) Set hoist lever in RAISE position and check until body is raised.
sensor
Change between
Between BRC1 (8) – (21) Voltage
0–5V
out.)
46 HD465-7R, HD605-7R
HD465-7R, HD605-7R 47

© 2007 KOMATSU
All Rights Reserved
48 HD465-7R, HD605-7R
SEN02543-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
H-1 Machine does not start............................................................................................................................. 4
H-2 Machine does not travel smoothly (hunting) ............................................................................................ 6
H-3 Lockup cannot be cancelled..................................................................................................................... 6
H-4 Excessive shock when starting or shifting excessive ............................................................................... 7
H-5 Transmission does not shift up................................................................................................................. 8
H-6 Machine lacks power or speed when traveling ...................................................................................... 10
H-7 Time lag is excessive when starting or shifting gear .............................................................................. 14
H-8 Torque converter oil temperature is high................................................................................................ 16
H-9 Torque converter oil pressure is low....................................................................................................... 17
H-10 Front brake is ineffective ...................................................................................................................... 18
H-11 Rear brake is ineffective ....................................................................................................................... 19
H-12 Steering wheel is heavy ....................................................................................................................... 20
H-13 Steering wheel does not work .............................................................................................................. 21
HD465-7R, HD605-7R 1
H-14 Steering wheel vibrates ........................................................................................................................ 22

H-15 Dump body lifting speed is slow ........................................................................................................... 23
H-16 Dump body does not work.................................................................................................................... 24
H-17 Excessive hydraulic drift of dump body ................................................................................................ 25
2 HD465-7R, HD605-7R

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
2
Possible causes Cause for presumed failure <Contents>
and standard (The attached No. is for fil-
value in normal • The standard values in normalcy by which to judge “Good“
3 ing and reference purpose
state or “No Good“ about presumed causes.
only. It does not stand for
any priority.) • References for making judgement of “Good“ or “No Good“
4
HD465-7R, HD605-7R 3
H-1 Machine does not start 1

Trouble Machine does not start at any gear speed.
• Before carrying out troubleshooting, check that transmission oil level is normal.
• If failure code related to input shaft speed sensor system or mechanical system is displayed, carry
Related
information
• Check that drive shaft etc. is free from abnormality.
• Check that parking brake is reset securely.

Defective power train pump
1 Power train pump strainer may be clogged. Check it directly.
strainer
Air in suction side of power Suction piping of power train pump may have sucked air. Check it
2
train pump directly.
a Prepare with engine stopped, then start engine and carry out
troubleshooting at high idle.
Defective power train pump • Engine speed: 2,000 rpm (Rated speed)
3
main relief valve 3.68 ± 0.2 MPa
F1 – F3, R
Relief oil {37.5 ± 2.0 kg/cm2}
pressure 2.19 ± 0.2 MPa
F4 – F7
{23.2 ± 2.0 kg/cm2}
Defective torque converter • Engine speed: 2,000 rpm (Rated speed)
4
oil pressure (relief valve) 0.74 ± 0.05 MPa
Torque converter inlet pressure
{7.5 ± 0.5 kg/cm2}
Possible causes Torque converter outlet pres- 0.59 ± 0.05 MPa

and standard sure {6 ± 0.5 kg/cm2}
value in normal a Prepare with engine stopped, then start engine and carry out
state 5 Defective torque converter troubleshooting at high idle.
Stall speed (Power mode) 1,910 ± 100 rpm
• Engine speed: 2,000 rpm (Rated speed)
1.91 ± 0.2 MPa
Low clutch
{19.5 ± 2.0 kg/cm2}
1.72 ± 0.2 MPa
High clutch
{17.5 ± 2.0 kg/cm2}
Defective gear speed clutch 1.67 ± 0.2 MPa
6 4th clutch
ECMV {17.0 ± 2.0 kg/cm2}
1.86 ± 0.2 MPa
3rd clutch
{19.0 ± 2.0 kg/cm2}
3.28 ± 0.2 MPa
2nd clutch 1st clutch
{33.5 ± 2.0 kg/cm2}
3.19 ± 0.25 MPa
Reverse clutch
{32.5 ± 2.5 kg/cm2}
* Since gear speed clutches are combined and operated 2 sets by
2, see combinations in Table 1.
4 HD465-7R, HD605-7R

• If oil pressure checked in Cause 6 is low, oil may be leaking
through clutch seal ring.
7 Defective gear speed clutch
Possible causes • If oil pressure checked in Cause 6 is normal, clutch may be slip-
and standard ping.
value in normal • If check result of Cause 3 is abnormal, disconnect power train
state 8 Defective power train pump pump outlet hose and crank engine to see if oil flows out.
• Check line filter for foreign matter to judge.
Internal defect in transmis-
9 Transmission may have defect in it. Check it directly.
sion
Table 1
Operated clutches
Lo Hi 1st 2nd 3rd 4th R
F1 q q
F2 q q
F3 q q
Gear speed
F4 q q
F5 q q
F6 q q
F7 q q
N
R q q
HD465-7R, HD605-7R 5
H-2 Machine does not travel smoothly (hunting) 1

Trouble Machine does not travel smoothly (hunting).
Related • Check that the transmission oil level is correct.
information • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
Possible causes • Oil temperature: 80 °C
and standard Defective power train pump • Engine speed: 2,000 rpm (Rated speed)
value in normal 3
state F1 – F3, R
F4 – F7
{23.2 ± 2.0 kg/cm2}
• If the oil pressure is low in the item 3, wear of the gear speed
clutch piston seal ring or wear of the ring groove can be sus-
4 Defective gear speed clutch pected.
• If the oil pressures are within the ranges in the item 3, a slip of
the clutch can be suspected.
H-3 Lockup cannot be cancelled 1

Trouble Torque converter lockup cannot be cancelled.

Possible causes • Oil temperature: 80 °C
Defective lockup solenoid
and standard 1
valve • Engine speed: 2,000 rpm (Rated speed)
value in normal
state Lockup solenoid valve output 1.67 ± 0.2 MPa
pressure {17.0 ± 2.0 kg/cm²}
If the oil pressure is within the range in the item 1, a seizure of the
2 Defective lockup clutch
lockup clutch can be suspected.
6 HD465-7R, HD605-7R
H-4 Excessive shock when starting or shifting excessive 1

Trouble Shock when starting or shifting is excessive.
Related
• If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information

* 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
Possible causes cases.
and standard • When it is apparent that the shock suddenly became severer
value in normal Defective gear speed clutch than before.
1
state ECMV
• The shock is severer compared with other machines of the same
class.
Since the operation of the gear speed clutch ECMV can be
suspected to be defective, check it directly.
HD465-7R, HD605-7R 7
H-5 Transmission does not shift up 1

Trouble Transmission does not shift up.
Related
information • If the brake lamp lights up while the foot brake (service brake), retarder brake or secondary brake is
not operated, carry out repair first.

1
F1 – F3, R
F4 – F7
{23.2 ± 2.0 kg/cm2}
Defective lockup solenoid • Oil temperature: 80 °C
2
Lockup solenoid valve output 1.91 ± 0.15 MPa
If the shit up operations take place when traveling down a slope,
3 Defective lockup clutch
a slip of the lockup clutch can be suspected.
Possible causes troubleshooting at high idle.
and standard • Oil temperature: 80 °C
value in normal • Engine speed: 2,000 rpm (Rated speed)
state
1.91 ± 0.2 MPa
Low clutch
{19.5 ± 2.0 kg/cm2}
1.72 ± 0.2 MPa
High clutch
{17.5 ± 2.0 kg/cm2}
Defective gear speed clutch 1.67 ± 0.2 MPa
4 4th clutch
ECMV {17.0 ± 2.0 kg/cm2}
1.86 ± 0.2 MPa
3rd clutch
{19.0 ± 2.0 kg/cm2}
3.28 ± 0.2 MPa
{33.5 ± 2.0 kg/cm2}
3.19 ± 0.25 MPa
Reverse clutch
{32.5 ± 2.5 kg/cm2}
Defective gear speed clutch
5 pected.
piston
• If the oil pressure is within the range in the item 4, a slip of the
gear speed clutch piston can be suspected.
8 HD465-7R, HD605-7R
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
Gear speed
F4 q q
F5 q q
F6 q q
F7 q q
N
R q q
HD465-7R, HD605-7R 9
H-6 Machine lacks power or speed when traveling 1

Trouble (1) When abnormality is present at all gear speeds (when traveling in lockup range).
• Check that the transmission oil level is correct.
Related • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information • Check that the parking brake is completely released and also check for dragging of the retarder brake.
• Check that the tire inflation pressure is proper.

Defective power train pump The power train pump strainer is suspected to be clogged, check it
1
strainer directly.
Air sucked in at the suction Since the air can be suspected to be sucked in from the suction
2
side of the power train pump piping of the power train pump, check it directly.
3
F1 – F3, R
F4 – F7
{23.2 ± 2.0 kg/cm2}
Possible causes a Prepare with engine stopped, then start engine and carry out
and standard
value in normal
state Defective lockup solenoid • Oil temperature: 80 °C
4
Lockup solenoid valve output 1.67 ± 0.2 MPa
• If the oil pressure is low in the item 4, wear of the lockup clutch
piston seal ring or wear of the ring groove can be suspected.
5 Slip of lockup clutch
• If the oil pressures are within the ranges in the item 4, a slip of
the lockup clutch piston can be suspected.
If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
Check for aluminum worn powder etc. residing on the line filter.
If no problem is found in item 1 through 6, measure the torque
converter stall speed (in the power mode: 1,910 ± 100 rpm). If it is
7 Decrease of engine output
below the standard value, the deterioration of the engine unit per-
formance can be suspected.
10 HD465-7R, HD605-7R
Trouble (2) When machine lacks power or speed while traveling in torque converter range.
information • Check for oil leaking from the piping to the outside.
• Check that the parking brake is completely released and also check for dragging of the retarder brake.

a Prepare with the engine stopped and troubleshooting with
engine running at low idle and high idle.
Defective power train pump 3.68 ± 0.2 MPa
1 F1 – F3, R
main relief valve Relief oil {37.5 ± 2.0 kg/cm2}
F4 – F7
Possible causes {23.2 ± 2.0 kg/cm2}
and standard a Prepare with the engine stopped and troubleshooting with the
value in normal engine running at high idle.
state
Defective torque converter 0.74 ± 0.05 MPa
2 Torque converter inlet pressure
oil pressure {7.5 ± 0.5 kg/cm²}
Torque converter outlet pres- 0.59 ± 0.05 MPa
sure {6.0 ± 0.5 kg/cm²}
a Prepare with the engine stopped and troubleshooting with the
3 Defective torque converter engine running at high idle.
Stall speed (power mode) 1,910 ± 100 rpm
HD465-7R, HD605-7R 11
Trouble (3) Machine lacks speed or power when traveling in certain gear speeds.

• Oil leak tester: 80 °C
1.91 ± 0.2 MPa
Low clutch
{19.5 ± 2.0 kg/cm2}
1.72 ± 0.2 MPa
High clutch
{17.5 ± 2.0 kg/cm2}
1.67 ± 0.2 MPa
Defective gear speed clutch 4th clutch
1 {17.0 ± 2.0 kg/cm2}
Possible causes ECMV
1.86 ± 0.2 MPa
and standard 3rd clutch
{19.0 ± 2.0 kg/cm2}
value in normal
state 3.28 ± 0.2 MPa
{33.5 ± 2.0 kg/cm2}
3.19 ± 0.25 MPa
Reverse clutch
{32.5 ± 2.5 kg/cm2}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
Gear speed
F4 q q
F5 q q
F6 q q
F7 q q
N
R q q
12 HD465-7R, HD605-7R
HD465-7R, HD605-7R 13
H-7 Time lag is excessive when starting or shifting gear 1

Trouble Time lag is excessive when starting or shifting gear.
Related
• Check for oil leaking from the piping to the outside.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
3
F1 – F3, R
F4 – F7
{23.2 ± 2.0 kg/cm2}
1.91 ± 0.2 MPa
Low clutch
and standard 1.72 ± 0.2 MPa
value in normal High clutch
{17.5 ± 2.0 kg/cm2}
state
1.67 ± 0.2 MPa
Defective gear speed clutch 4th clutch
4 {17.0 ± 2.0 kg/cm2}
ECMV
1.86 ± 0.2 MPa
3rd clutch
{19.0 ± 2.0 kg/cm2}
3.28 ± 0.2 MPa
{33.5 ± 2.0 kg/cm2}
3.19 ± 0.25 MPa
Reverse clutch
{32.5 ± 2.5 kg/cm2}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
• If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
14 HD465-7R, HD605-7R
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
Gear speed
F4 q q
F5 q q
F6 q q
F7 q q
N
R q q
HD465-7R, HD605-7R 15
H-8 Torque converter oil temperature is high 1

Trouble Torque converter oil temperature is high.
Related
information • If the oil temperature goes up when the torque converter is stalled and goes down when the trans-
mission is returned to the neutral position, the machine is normal and overload operation is a cause
of the problem.

1
strainer directly.
2
Defective power train pump
3 The filter can be suspected to be clogged; visually check it.
line filter
4
F1 – F3, R
F4 – F7
and standard • If a defect is found in the item 4, the power train pump can be
value in normal 5 Defective power train pump suspected to be defective.
state Check for aluminum worn powder etc. residing on the line filter.
Defective torque converter • Oil temperature: 80 °C
6
relief valve • Engine speed: 2,000 rpm (Rated speed)
0.74 ± 0.05 MPa
{7.5 ± 0.5 kg/cm²}
7 Defective torque converter
0.74 ± 0.05 MPa
{7.5 ± 0.5 kg/cm²}
Torque converter outlet 0.59 ± 0.05 MPa
16 HD465-7R, HD605-7R
H-9 Torque converter oil pressure is low 1

Trouble Torque converter oil pressure is low.
Related
information
• Check for oil leaking from the piping to the outside.

1
strainer directly.
2
3
F1 – F3, R
F4 – F7
{23.2 ± 2.0 kg/cm2}
Possible causes • If a defect is found in the item 3, the power train pump can be
and standard 4 Defective power train pump suspected to be defective.
value in normal Check for aluminum worn powder etc. residing on the line filter.
state
Defective torque converter • Oil temperature: 80 °C
5
relief valve • Engine speed: 2,000 rpm (Rated speed)
0.74 ± 0.05 MPa
{7.5 ± 0.5 kg/cm²}
6 Defective torque converter
0.74 ± 0.05 MPa
{7.5 ± 0.5 kg/cm²}
Torque converter outlet 0.59 ± 0.05 MPa
HD465-7R, HD605-7R 17
H-10 Front brake is ineffective 1

Trouble Front brake is ineffective.
Related
information

Air sucked in at the suction
Since the air can be suspected to be sucked in from the suction
1 side of the brake control
piping of the brake control pump, check it directly.
pump
a Prepare with the engine stopped and measure with the engine
running at high idle.
Defective accumulator 17.6 ± 1.2 MPa
2 Charge valve cut-in pressure
charge valve {180 ± 12 kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Possible causes
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
and standard 3
front brake * [Reference] Charged gas pressure: 10.7 ± 0.34 MPa {109 ± 3.5
value in normal
state kg/cm²}
4 Defective front brake valve
Brake actuat- Brake pedal 18.4 (+0.76/–1.52) MPa
ing pressure operated {187.5 (+7.5/–16.5) kg/cm²}
When the initial response time of brake system is excessively long
Defective front brake slack
5 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4, a seal ring or ring groove
can be suspected to be defective.
6 Defective front disc brake
• If the oil pressures are within the range in the item 4, a slip of the
brake disc is suspected.
18 HD465-7R, HD605-7R
H-11 Rear brake is ineffective 1

Trouble Rear brake is ineffective.
Related
information

1 side of the brake control
piping of the brake control pump, check it directly.
pump
Defective accumulator 17.6 ± 1.2 MPa
2 Charge valve cut-in pressure
charge valve {180 ± 12 kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
rear brake * [Reference] Charged gas pressure: 6.2 ± 0.2 MPa {63 ± 2 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective rear brake valve
Brake actuat- Brake pedal 9.8 ± 0.69 MPa
ing pressure operated {100 ± 7 kg/cm²}
Defective rear brake retarder running at high idle.
5
pressure reducing valve Brake actuat- Retarder lever 8.7 ± 0.64 MPa
ing pressure operated {88.5 ± 6.5 kg/cm²}
When the initial response time of brake system is excessively long
Defective rear brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective rear wheel brake
• If the oil pressures are within the range in the item 4 and 5, a slip
of the brake disc is suspected.
HD465-7R, HD605-7R 19
H-12 Steering wheel is heavy 1

Trouble Steering wheel is heavy.
• Check that oil level in hydraulic tank is proper.
• If failure code related to mechanical system is displayed, carry out troubleshooting for it first.
• Check that play of steering wheel is normal (max. 150 mm).
Related • Check that hinge pins etc. are greased thoroughly.
information • Before starting carry out troubleshooting, adjust tire inflation pressure to proper level.
"Standard tire"
"HD465-7E0" "HD605-7E0"
24.00-35-36PR (Front and rear wheels) 24.00R35 (Front and rear wheels)
(0.47 ± 0.01 MPa {4.75 ± 0.1 kg/cm2}) (0.69 ± 0.01 MPa {7.0 ± 0.1 kg/cm2})

Air in suction side of steering Suction piping of steering and work equipment pump may have
1
and work equipment pump sucked air. Check it directly.
Defective steering and work Steering and work equipment pump strainer may be clogged.
2
equipment pump strainer Check it directly.
Defective relief valve of troubleshooting at high idle.
3
demand valve Relief pressure (Cylinder stroke 22.5 ± 0.98 MPa
end) {230 ± 10 kg/cm2}
Possible causes 4 Defective steering valve
and standard Relief pressure (Cylinder stroke 22.5 ± 0.98 MPa
value in normal end) {230 ± 10 kg/cm2}
state Malfunction of demand valve If oil pressure is normal, demand valve spool may be malfunction-
5
spool ing. Check it directly.
Relief pressure (Cylinder stroke 22.5 ± 0.98 MPa
6 Defective steering cylinder end) {230 ± 10 kg/cm2}
If oil pressure is low, disconnect hydraulic hose on steering cylin-
der head side and relieve at stroke end. If oil flows from cylinder
side, piston ring of cylinder is defective.
If oil pressure check in Causes 3 and (4) is low, steering and work
Defective steering and work
7 equipment pump may be defective. Check line filter for aluminum
equipment pump
chips.
20 HD465-7R, HD605-7R
H-13 Steering wheel does not work 1

Trouble Steering wheel does not work.
• Check that the oil level in the hydraulic tank is correct.
information • Check that the steering wheel play is correct (less than 150 mm).
• Check that the hinge pin, etc. are greased fufficiently.

If the dump body also does not work, the PTO can be suspected to
1 Defective PTO
be defective.
2 side of the steering and work
side of the steering and work equipment pump, check it directly.
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
3
equipment pump strainer clogged, visually check it.
Defective relief valve of engine running at high idle.
4
demand valve Relief oil pressure (cylinder 22.5 ± 0.98 MPa
stroke end) {230 ± 10 kg/cm²}
Possible causes
engine running at high idle.
and standard 5 Defective steering valve
value in normal Relief oil pressure (cylinder 22.5 ± 0.98 MPa
state stroke end) {230 ± 10 kg/cm²}
Defective operation of If the oil pressure is within the range, the operation of the demand
6
demand valve spool valve spool can be suspected to be defective: check it directly.
Relief oil pressure (cylinder 22.5 ± 0.98 MPa
stroke end) {230 ± 10 kg/cm²}
7 Defective steering cylinder
When the oil pressure is low, disconnect the hydraulic hose in the
steering cylinder head side and relieve the pressure at the stroke
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If the oil pressure is low in the item 4 or 5, the steering and work
Defective steering and work
8 equipment pump can be suspected to be defective.
equipment pump
HD465-7R, HD605-7R 21
H-14 Steering wheel vibrates 1

Trouble Steering wheel vibrates.
Related • Check that the oil level in the hydraulic tank is correct.

1 Defective oil Check for deterioration of oil.
Relief oil pressure (cylinder 22.5 ± 0.98 MPa
Possible causes stroke end) {230 ± 10 kg/cm²}
and standard 2 Defective steering cylinder
value in normal
steering cylinder head side and relieve the pressure at the stroke
state
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If relief pressure (demand valve relief pressure) of steering circuit
Defective crossover relief is normal and piston rings of hydraulic cylinder checked in Cause 2
3
valve is also normal, "crossover relief valve" may be defective. (Replace
valve.)
22 HD465-7R, HD605-7R
H-15 Dump body lifting speed is slow 1

Trouble When lifting dump body, the speed is slow and the power is insufficient.
Related
information
• Check that the dump lever moves smoothly.

1 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
2
and steering pump strainer clogged, visually check it.
3
demand valve Relief oil pressure (steering 22.5 ± 0.98 MPa
cylinder stroke end) {230 ± 10 kg/cm²}
Defective dump EPC valve engine running at high idle.
4 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
If the oil pressure is low in the item 4, the operation of the dump
Possible causes Defective operation of dump
5 EPC valve can be suspected to be defective; visually check the
and standard EPC valve
valve.
value in normal
If the oil pressure is low in the item 4, the pilot pump for the dump
state Defective pilot pump for
6 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
7
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 7,
Defective operation of the
8 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
stroke end) {210 (+10/0) kg/cm²}
9 Defective dump cylinder
dump cylinder head side and relieve the pressure at the raise
stroke end. If the oil comes out from the cylinder side, the cylinder
piston ring is defective.
HD465-7R, HD605-7R 23
H-16 Dump body does not work 1

Trouble Dump body does not work.
Related
information
• Check that the dump lever moves smoothly.

If the steering also does not work, the PTO can be suspected to be
1 Defective PTO
defective.
2 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
3
and steering pump strainer clogged, visually check it.
4
demand valve Relief oil pressure (steering 22.5 ± 0.98 MPa
cylinder stroke end) {230 ± 10 kg/cm²}
Defective dump EPC valve engine running at high idle.
5 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
Possible causes If the oil pressure is low in the item 5, the operation of the dump
and standard Defective operation of dump
6 EPC valve can be suspected to be defective; visually check the
value in normal EPC valve
valve.
state
If the oil pressure is low in the item 5, the pilot pump for the dump
Defective pilot pump for
7 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
8
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 8,
Defective operation of the
9 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
stroke end) {210 (+10/0) kg/cm²}
dump cylinder head side.
If the oil comes out from the cylinder side at the raise stroke end,
the cylinder piston ring is defective.
24 HD465-7R, HD605-7R
H-17 Excessive hydraulic drift of dump body 1

Trouble Hydraulic drift of dump body is excessive.
Related
information

a Raise the dump body and troubleshooting with the engine
stopped.
Defective oil tightness of Raise the dump body and disconnect the hydraulic hose in the
Possible causes 1
hoist valve main spool dump cylinder head side.
and standard
value in normal If the oil flows out from the cylinder side, the oil tightness of the
state spool is defective.
Raise the dump body and disconnect the hydraulic hose in the
dump cylinder head side.
If the oil does not flow out from the cylinder side, the cylinder piston
ring is defective.
HD465-7R, HD605-7R 25

© 2007 KOMATSU
All Rights Reserved
26 HD465-7R, HD605-7R
SEN02544-00
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 4
S-1 Starting performance of engine is poor .................................................................................................... 8
S-2 Engine does not start ............................................................................................................................... 9
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operation................................................................................................................ 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lack output (or lacks power) ....................................................................................................... 15
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 16
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 18
S-9 Oil becomes dirty quickly........................................................................................................................ 19
S-10 Fuel consumption is excessive............................................................................................................. 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 21
S-12 Oil pressure drops ................................................................................................................................ 22
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 23
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 24
HD465-7R, HD605-7R 1
S-15 Abnormal noise is made ....................................................................................................................... 25

S-16 Vibration is excessive ........................................................................................................................... 26
2 HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Method of using troubleshooting chart 1

The troubleshooting chart consists of the [Questions], [Check items], [Causes], and [Troubleshooting]
blocks.
The [Questions] and [Check items] are used to pinpoint high probability [Causes] by simple inspection or
from phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed [Causes] in order from the
most probable one to make final confirmation according to the [Troubleshooting] procedure.
[Questions]
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The
items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
[Check items]
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on
the right.
[Causes]
Items to be narrowed from the questions and check items. The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the [Causes], apply the items marked with w before those marked with Q.
When narrowing the [Causes], do not apply the items marked with E. (If no items have other marks
and the causes cannot be narrowed, however, you may apply them.)
4 HD465-7R, HD605-7R
HD465-7R, HD605-7R 5
<Example of troubleshooting> Exhaust gas is black(Incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust gas slowly became
black", "Power slowly became weaker", and "Dust indicator is lighting red".
6 HD465-7R, HD605-7R
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
HD465-7R, HD605-7R 7
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
Defective electrical system
Leaking or clogged fuel piping or entry of air

q
Clogged air breather hole of fuel tank cap

q Insufficient supply of fuel
Defective contact of valve and vale seat
Defective alternator (generator section)

Defective alternator (regulator section)
Insufficient intake of air
Stuck or seized supply pump plunger

q
Defective intake air heater system

q Improper selection of fuel
Defective or deteriorated battery

Clogged feed pump gauze filter
a The common rail fuel injection system (CRI) controled
Clogged air cleaner element

the fuel injection timing electrically. Accordingly, even if
Clogged fuel filter element

Worn piston ring, cylinder
the starting operation is carried out, the engine may not
start until the crankshaft revolves 2 turns at maximum.
Defective injector
This phenomenon does not indicate a trouble, however
Confirm recent repair history

Degree of use of
machine Operated for long period E E E E
Became worse gradually Q w w Q Q

Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is used Q Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge
(if monitor is installed) w w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Priming pump is too light or too heavy to operate w Q Q
Starting motor cranks engine slowly w
While engine is When air bleeding plug of fuel filter is removed, fuel does not flow
out w w
rotated with starting
motor w
Check items
When spill hose from injector is disconnected, little fuel spills

Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Compression pressure is low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and element directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage of 20 – 30 V generated between alternator terminals B and E while Yes q
engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Displayed failure codes: [CA559] and [CA2249]
8 HD465-7R, HD605-7R
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Defective starting motor (safety relay section)

q Seized internal parts of engine
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operation"
q Water hammer caused by coolant which entered cylinder

q Defective electrical system
Defective starting circuit wiring

q Trouble in drive devices on applicable machine side
Broken flywheel ring gear

o Carry out troubleshooting for devices on applicable machine
Defective starting switch

Defective battery relay
Questions
Degree of use of
Operated for long period E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
Carry out troubleshooting

Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminals B and E q

Turn starting switch When terminals B and C of starting switch are connected, engine starts q
OFF, connect cables, When terminals B and C at safety relay outlet are connected, engine
on E-mode
turn starting switch ON, starts q
and carry out trouble-
shooting Even if terminals B and C at safety relay outlet are connected, engine
q
does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
HD465-7R, HD605-7R 9
b) Engine rotates but no exhaust gas comes out Causes

General causes why engine rotates but no exhaust gas
Malfunction of overflow valve (Does not close)

comes out

Fuel is not supplied
Wrong connection of supply pump PCV

q
Seized or abnormally worn feed pump

q Supply of fuel is extremely small
Broken supply pump shaft or key

q Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Malfunction flow damper

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Confirm recent repair history E
Questions
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Check items
Fuel is leaking from fuel piping w

When air bleeding plug of fuel filter is removed, fuel does
While engine is Q Q w Q
not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel
spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to supply pump low pressure "Rail Press
q q q
(Very) Low Error (*1)" indicated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
q
Short/Open Error (*3)" indicated by code
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure codes [CA559] and [CA2249]

10 HD465-7R, HD605-7R
c) Exhaust gas comes but engine does not start Causes
Defective coolant temperature sensor or wiring harness

(fuel is injected)
Worn dynamic valve system (Valve, rocker lever, etc.)

General causes why exhaust gas comes out but engine does
not startt
Leaking or clogged fuel system or entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Clogged injector or defective spray
Defective intake air heater system

Worn piston ring or cylinder liner

Clogged fuel filter or strainer
Use of improper fuel

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is used Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged Q
There are rust and water in fuel drained from fuel tank w w
There is not fuel in removed fuel filter w
Starting motor rotates engine slowly w
When engine is rotated, abnormal sound comes out from around cylinder head w
Check items
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting
Inspect fuel filter and strainer directly q

Carry out troubleshooting according to supply pump low pressure "Rail Press (Very) Low
Error (*1)" indicated by code q
When injector unit is tested, spray condition is bad q

Coolant temperature gauge does not indicate normally (if it is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
HD465-7R, HD605-7R 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Malfunction of flow damper (Large leakage from injector)

q
Seized turbocharger or interference of turbocharger

q Defective condition of fuel spray

q Control by controller in derate mode

Defective contact of valve and valve seat
(limiting injection rate (output) because of an error in

electrical system)
Clogged injector or defective spray


Improper valve clearance

Degree of use of Operated for long period E E E E E
machine
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is used w w w w
Filters have not been replaced according to Operation and Maintenance Manual w w w
Oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Q w
Blue under light load w
Exhaust gas color
Black w Q w w
Check items
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w

Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 HD465-7R, HD605-7R
S-4 Engine stops during operation 1

General causes why engine stops during operation Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side

q Overheating
Defective engine controller power supply wiring

q Trouble in drive devices on applicable machine
Broken or seized piston or connecting rod

side
o Carry out troubleshooting for devices on appli-

Broken or seized crankshaft bearing
cable machine
Broken supply pump shaft or key

Defective starting switch wiring

Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Degree of use of
Operated for long period EE
machine
Made abnormal noise stopped suddenly w w w w Q w Q w w
w Q Q
Questions
Overheated and stopped

Engine
Stopped slowly w Q Q Q Q
Hunted and stopped w Q Q Q Q Q Q
Non-specified fuel is used Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
w w
Manual
Fuel level monitor indicates low level (if monitor is installed) w
There are metal particles in oil drained from oil pan w w w
Check items
Engine does not rotate at all w w

When engine is Engine rotates in opposite direction w
rotated with hand Engine moves by gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w

Inspect piston and connecting rod directly q

on applicable machine
Inspect crankshaft bearing directly q

Inspect gear train directly q
Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting according to supply pump low pressure "Rail q q
Press (Very) Low Error (*1)" indicated by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
is removed q
Check the controller power supply wiring q

Check the starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
—
Add
HD465-7R, HD605-7R 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Malfunction of flow damper (Large leakage from injector)

q
q Defective speed sensor
Clogged injector or defective spray (dirt in injector)

(Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness

Low setting of low idle speed

Degree of use of machine Operated for long period E E
Q Q Q
Questions
At a certain speed range

At low idle w Q Q Q Q Q Q Q
Engine hunts
Even when speed is raised Q Q Q
On slopes w Q Q
Filters have not been replaced according to Operation and Maintenance Manual w w
Check items
There are rust and water in fuel drained from fuel tank Q Q

q
Troubleshooting
Inspect feed pump gauze filter directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
change
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code q
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure code [CA689]

*2: Displayed failure code [CA778]
14 HD465-7R, HD605-7R
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of charge pressure sensor (air leakage)

q
q Defective spray condition of fuel
Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness
Clogged injector or defective spray (dirt in injector)

q Overheating
Defective drive of injector (signal or solenoid)

o See "S-14 Coolant temperature becomes too

high (Overheating)"

Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping


error in electrical system)

Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w w
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low w
When engine is rotated, interference sound comes out from around
w
Check items
turbocharger
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
Boost pressure is low q q q
Troubleshooting

Carry out troubleshooting according to supply pump low pressure "Rail Press
(Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Charge Air Press Sensor High (Low)
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
HD465-7R, HD605-7R 15
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
Leakage of air between turbocharger and cylinder head

q
q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

Overheating

q
o See "S-14 Coolant temperature becomes too high

(Overheating)"
Improper fuel injection pressure

Crushed or clogged muffler

(limiting injection rate (output) because of an error
Clogged or seized injector

Abnormally worn injector

in electrical system)

Suddenly became black w Q Q
w Q Q Q
Questions
Exhaust gas color Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head or clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q
Check items
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

Troubleshooting
When muffler is removed, exhaust gas color improves q

Error (*1)" indicated by code q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q
change
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sensor High (Low) Error (*2)"
indicated by code q
Check with monitoring function (*3). q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
16 HD465-7R, HD605-7R

*3: Referring to Testing and adjusting, "Special functions of machine monitor", Service mode, check Temper-
ature measured by coolant temperature sensor: Monitoring codes [04104] (°C) and [04105] (V).
HD465-7R, HD605-7R 17
S-8 Oil consumption is excessive (or exhaust gas is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
continuously)
Clogged breather or breather hose

Dust sucked in from intake system
q External leakage of oil

Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes dirty quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust gas is blue under light load w w
Excessive Q Q Q w w
Amount of blow-by gas
None w
There is dust in intake manifold q

Inside of intake manifold is abnormally dirty q
Troubleshooting
Play of turbocharger shaft is excessive q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q q
Oil leaks out of engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 HD465-7R, HD605-7R
S-9 Oil becomes dirty quickly 1

General causes why oil becomes dirty quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine side
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Overload operation
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Clogged oil cooler
Clogged oil filter
Questions
Degree of use of machine Operated for long period E E E

Non-specified fuel is used Q
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
(if monitor is installed)
There are metal particles in oil drained from oil filter Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust gas is
Black w
Comes out excessively Q Q w
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Troubleshooting
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
—
HD465-7R, HD605-7R 19
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
Leakage of fuel

q
q Defective condition of fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
q The engine is operated in the low-temperature mode while it is not
warmed up sufficiently (Coolant temperature sensor: -5 °C or less).
Fuel leakage from fuel filter, piping, etc.

Accordingly, more fuel is consumed. This does not indicate abnormal-
Defective common rail fuel pressure

ity, however.
Fuel leakage inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective spray by injector

Malfunction of injector
E E E
Questions

Is large compared to other machines of same model Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w w
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q
Exhaust gas is
White Q
Remove head cover and inspect inside directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to supply pump low pressure "Rail Press (Very) Low Error (*1)"
q
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code q
Check with monitoring function (*3) q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy

*3: q Check the common rail fuel pressure by monitoring codes [36400] (MPa) and [36402] (V).
q Check the temperature measured by the coolant temperature sensor by monitoring codes [04104] (°C)
and [04105] (V).
a See Testing and adjusting, "Special functions of machine monitor", Service mode.
20 HD465-7R, HD605-7R
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down) 1
General causes why oil is in coolant Causes
q Leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting
Broken hydraulic oil cooler or power train oil cooler on

q Leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring
applicable machine side

Crack in cylinder block
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator and coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water flows out w
Carry out troubleshooting on

Leakage from cylinder head is detected by pressure test q
applicable machine side

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Leakage from oil cooler is detected by pressure test q

Replace
Replace
Replace
Replace
Replace
Remedy
—
HD465-7R, HD605-7R 21
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage from, clogging, or wear of lubrication system
Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping
q Defective oil pressure control
Defective oil level sensor or wiring harness

q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E E E
Questions

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is used Q Q
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle w Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil lever drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

There are metal particles in oil drained from oil pan w
There are metal particles in oil drained from oil filter w Q
There are metal particles in oil filter q

Inspect oil pan strainer and pipe directly q q
Troubleshooting
Oil pump is heavy to rotate or it has play q

See S-13
Valve spring of oil pump relief valve is fatigued or damaged q

Inspect oil filter directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)" q
indicated by code
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
—
Add
22 HD465-7R, HD605-7R
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump and compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-

ant"

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, water drops from muffler Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles come out or w
Q
Check items
coolant spurts back

Exhaust gas is white Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber on applicable machine side is low w
Oil level in hydraulic tank on applicable machine is low w

Remove and inspect head cover directly q
Troubleshooting
Inspect cylinder block and liner directly q q

Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q
Remove and inspect water pump directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
HD465-7R, HD605-7R 23
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation or damage of fan)
Rise of power train oil temperature on applicable machine side

q Drop in heat dissipation efficiency

q Trouble in coolant circulation system
q Rise of oil temperature in power train
o Carry out troubleshooting on applicable machine side
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Slipping fan belt or worn fan pulley

Clogged or crushed radiator fins
Clogged or broken oil cooler
Malfunction of thermostat
Clogged radiator core

Broken water pump
Low coolant level
Questions
Occurred suddenly Q w Q
Overheating
Always Q w w Q
Coolant temperature Rises quickly Q w
gauge Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover on applicable
machine side w w
Coolant is leaking because of cracks in hose or loose clamps w

Coolant flows out from radiator overflow hose w
Fan belt squeaks under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
w
temperature (if oil temperature gauge and coolant temperature gauge are installed)

Inspect cylinder liner directly q
Inspect oil cooler directly q

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

Thermostat does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
on H-mode
Inspect radiator core directly q

Cracking pressure of radiator cap is low q
Inspect fan belt and pulley directly q
Coolant temperature is normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
—
Add
24 HD465-7R, HD605-7R
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Broken output shaft, parts in damper on applicable machine side

Deformed cooling fan, loose fan belt, or interference of fan belt
q Abnormal combustion
q Air sucked in from intake system
Leakage of air between turbocharger and cylinder head
Broken dynamic valve system (valve, rocker lever, etc.)

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
Interference of turbocharger or seized turbocharger
Defective inside of muffler (Removal of bulkhead)

a The engine is operated in the low-temperature mode while
Excessive wear of piston ring or cylinder liner

it is not warmed up sufficiently. Accordingly, the engine
sound becomes a little larger. This does not indicate
Removed or seized gear train bushing

abnormality, however
a When the engine is accelerated, it is operated in the accel-
eration mode and its sound becomes a little larger for up to
Improper gear train backlash

about 5 seconds. This does not indicate abnormality, how-
Clogged or seized injector

ever
Dirt caught in injector

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is used Q
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w Q

Exhaust gas is
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
change
Abnormal noise comes out only at start of engine q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
HD465-7R, HD605-7R 25
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and applicable machine
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trouble-
shooting for "S-15 Abnormal noise is made", too
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts or broken cushions

Worn main bearing or connecting rod bearing
Worn front support spigot joint

Improper gear train backlash
Worn camshaft bushing
E E E E
Questions

Suddenly increased Q
Vibration
Gradually increased Q Q Q Q
There are metal particles in oil drained from oil filter w w
There are metal particles in oil drained from oil pan w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at medium speed Q

Vibration follows engine speed Q Q Q Q
Exhaust gas is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
Radial runout or facial runout is detected q
Inspect front support spigot joint directly q
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
26 HD465-7R, HD605-7R
HD465-7R, HD605-7R 27

© 2007 KOMATSU
All Rights Reserved
28 HD465-7R, HD605-7R
SEN02313-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
90 Diagrams and drawings 1

Hydraulic circuit diagram
Power train hydraulic circuit diagram .............................................................................................................. 2
Steering and hoist hydraulic circuit diagram ................................................................................................... 3
Brake hydraulic circuit diagram....................................................................................................................... 5
HD465-7R, HD605-7R 1
SEN02313-00 90 Diagrams and drawings
Power train hydraulic circuit diagram 1
2 HD465-7R, HD605-7R
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HD465-7R, HD605-7R
HD465-7R, HD605-7R 5

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R
SEN02314-01
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
90 Diagrams and drawings 1

Electrical circuit diagram
Electrical circuit diagram inside cab (1/2) ....................................................................................................... 3
Electrical circuit diagram outside cab (2/2) ..................................................................................................... 5
Connectors table and arrangement drawing................................................................................................... 7
HD465-7R, HD605-7R 1
2 HD465-7R, HD605-7R
Electrical circuit diagram for inside cab (1/2)
HD465-7R, HD605-7R
Electrical circuit diagram for inside cab (1/2) HD465-7R, HD605-7R
SEN02314-01
HD465-7R, HD605-7R 3
Electrical circuit diagram for outside cab (2/2)
HD465-7R, HD605-7R
Electrical circuit diagram for outside cab (2/2) HD465-7R, HD605-7R
SEN02314-01
HD465-7R, HD605-7R 5
Connectors table and arrangement drawing
Connectors table and arrangement drawing HD465/605-7R HD465/605-7R
Type of Number Type of Number Type of Number Type of Number

ConnectorNo. connector of pin Location Address ConnectorNo. connector of pin Location Address ConnectorNo. connector of pin Location Address ConnectorNo. connector of pin Location Address
53 Terminal 1 Emergency steering relay B-8 CJD DT2 6 Joint connector B-6 FL06 DT2 3 Ambient temperature sensor F-1 PR03 M 3 Front combination lamp (right) B-5
54 Terminal 1 Emergency steering relay B-7 CJE3 DT2B 8 Joint connector M-5 FLS 4 Flasher PR04 One-pin 1 Beacon lamp (right) (if equipped) B-5
connector
55 Terminal 1 Emergency steering relay B-7 CJE4 DT2B 8 Joint connector J-9 FOG M 6 Fog lamp switch (if equipped) AA-1
PR06 M 2 Fog lamp (right) (if equipped) B-5
56 Terminal 1 Emergency steering relay B-7 CJG DT2 6 Joint connector M-8 FR01 DT2 2 Air cleaner clogging sensor C-7
PR07 Terminal 1 Ground B-4
58 Terminal 1 Battery relay C-8 CJH1 DT2B 8 Joint connector FUA1 Circuit breaker (30A) B-6
PSOLR DT2 2 Parking brake solenoid M-5
59 Terminal 1 Battery relay C-8 CJK DT2 6 Intermediate connector D-8 FUA2 Circuit breaker (30A) B-7
PSWR DT2 2 Parking brake switch M-4
60 Terminal 1 Battery relay D-8 CJL DT2 6 Joint connector FUB1 Circuit breaker (80A) A-6
PWL_F 1 Power window motor (left) I-2
61 Terminal 1 Battery relay D-8 CJN DT2 6 Joint connector FUB2 Circuit breaker (80A) A-6
PWL_M 1 Power window motor (left) J-2
62 Terminal 1 Circuit breaker (80A) A-7 CJP DT2 6 Joint connector M-8 FUEL DT2 2 Fuel gauge sensor H-9
PWM M 6 Power mode switch P-4
63 Terminal 1 Circuit breaker (80A) A-7 CJP1 DT2 6 Joint connector I-9 G DT2 3 G sensor AN-9
PWR_F 1 Power window motor (right) E-8
64 Terminal 1 Circuit breaker (80A) B-6 CJP2 DT2 6 Joint connector J-9 GDL DT2B 12 Intermediate connector
PWR_M 1 Power window motor (right) F-8
65 Terminal 1 Circuit breaker (80A) A-6 CJPR DT2 6 Joint connector E-8 GND Terminal 1 Ground C-3
R01 Relay 5 Engine start relay AF-4
66 Terminal 1 Circuit breaker (30A) B-7 CJR DT2 6 Joint connector L-9 GS Terminal 1 Ground AM-6
R02 Relay 5 Transmission neutral relay AF-3
67 Terminal 1 Circuit breaker (30A) A-7 CJSL DT2 6 Joint connector I-9 H Terminal 1 Ground C-2
R03 Relay 5 Parking brake relay AF-3
68 Terminal 1 Circuit breaker (30A) B-7 CJV DT2 6 Joint connector L-9 H01 DT2 3 Steering pressure switch K-2
R04 Relay 5 Stop lamp relay AF-3
69 Terminal 1 Circuit breaker (30A) B-7 CJY DT2 6 Joint connector M-7 HAZ M 6 Hazard switch R-7
R05 Relay 5 Back lamp / buzzer relay AF-2
70 Terminal 1 Emergency steering relay B-8 CK1 M 6 Bulb breakage check switch Z-2 HEPC DT2 2 Hoist EPC valve M-5
R06 Relay 5 Fog lamp relay AG-4
71 Terminal 1 Emergency steering relay B-8 CM DT2C 8 Lighting switch, passing light switch, turn signal switch T-8 HM12 DT2 3 Blow-by sensor AM-6
R08 Relay 5 Stop lamp relay AF-3
72 Terminal 1 Emergency steering relay B-9 CN1 DT 2 Injector # 1 AJ-8 HM2130 2 Connector
R11 Relay 5 Horn relay AG-4
73 Terminal 1 Emergency steering relay B-9 CN10 DT2 2 3rd Clutch ECMV AE-9 HM2140 2 Connector
R14 Relay 5 BCV relay AF-4
74 Terminal 1 Battery relay B-9 CN11 DT2 2 3rd Fill switch AE-9 HM-21A 2 Exhaust temperature sensor
R16 Relay 5 Hazard relay 1 AF-1
75 Terminal 1 Battery relay B-9 CN12 DT2 2 R Clutch ECMV AE-9 HM-21B 2 Exhaust temperature sensor
R17 Relay 5 Hazard relay 2 AG-1
76 Terminal 1 Battery relay C-9 CN13 DT2 2 R Fill switch AE-9 HM-22A 2 Exhaust temperature sensor amp
R19 Relay 5 Parking brake safety relay AG-4
77 Terminal 1 Battery relay C-9 CN14 DT2 2 4th Clutch ECMV AE-9 HM-22B 2 Exhaust temperature sensor amp
R21 Relay 5 Side lamp relay AG-4
81 Terminal 1 Fuse (120A) D-8 CN15 DT2 2 4th Fill switch AD-9 HM-23A 2 Exhaust temperature sensor amp
R22 Relay 5 Revolving relay AH-3
83 Terminal 1 Fuse (120A) D-8 CN16 DT2 2 Toque converter rock up solenoid AD-8 HM-23B 2 Exhaust temperature sensor amp
R25 11 Power window relay AA-7
250 2 Resistor (male) S-8 CN17 DT2 2 Lo Clutch ECMV AD-8 HM-50 3 Connector
R29 Relay 5 Head lamp relay (Hi) (PASS) AH-2
1020 2 Resistor (male) S-8 CN18 DT2 2 Lo Fill switch AC-8 HM-55 3 Intermediate connector
R30 Relay 5 Head lamp relay (Hi) AH-1
A1 1 Connector AA-6 CN19 DT2 2 Hi Clutch ECMV AC-8 HM-81 8 Intermediate connector
R31 Relay 5 Head lamp relay (Lo)
ABS M 6 ABS system switch R-2 CN2 DT 2 Injector # 2 AJ-9 HM-CN1 20 VHMS & Payload meter controller
R32 Relay 5 Dust indicator relay AG-1
ABS1 DRC 24 ABS controller CN20 DT2 2 Hi Fill switch AD-8 HM-CN2A 18 VHMS & Payload meter controller
R33 M 6 Parking brake manual switch U-9
ABS2 DRC 40 ABS controller CN21 DT2 2 Torque converter intermediate oil puressure sensor AD-5 HM-CN2B 12 VHMS & Payload meter controller
R34 M 7 Power window switch (right) V-1
ABS3 DRC 40 ABS controller CN22 DT2 2 Torque converter oil temperature sensor AE-5 HM-CN3A 18 VHMS & Payload meter controller
R35 M 7 Power window switch (left) V-9
ABS6 4 Intermediate connector CN23 DT2 2 Transmission oil temperature sensor AG-5 HM-CN3B 12 VHMS & Payload meter controller
R37 Relay 5 Auto preheat relay AH-3
ABS7 DT2C 12 Intermediate connector CN26 DT2 2 Main pressure switch AC-7 HM-CN4A 14 VHMS & Payload meter controller
R40 Relay 5 Payload meter relay (if equipped) AH-2
ABS8 DT2B 12 Intermediate connector CN27 DT2 2 Main pressure fixed valve AC-6 HM-CN4B 10 VHMS & Payload meter controller
R43 Relay 5 Payload meter external indicator lamp blue relay AH-2
ABS9 DT2A 12 Intermediate connector CN3 DT2 2 Input shaft speed sensor AG-9 HN 1 Horn switch T-8
R44 Relay 5 Payload meter external indicator lamp yellow relay AH-1
AC1 M 6 Intermediate connector P-4 CN3 DT 2 Injector # 3 AK-9 HN1 DT2 2 Horn valve B-3
R45 Relay 5 Payload meter external indicator lamp red relay AH-1
ACC Terminal 1 Starting switch ACC terminal P-9 CN4 DT2 2 Intermediatet shaft speed sensor AG-9 HN2 DT2 2 Horn valve B-3
R46 5 Small lamp relay
ACCF DT2 3 ACC oil pressure sensor (front) M-4 CN4 DT 2 Injector # 4 AL-9 HN25 DT2 2 Battery isolator (if equipped) VHMS indicator
RAD 9 Cassette stereo AM/FM radio R-2
ACCR DT2 3 ACC oil pressure sensor (rear) L-3 CN5 DT2 2 Output shaft speed sensor AH-7 HSL DT2 4 Hoist lever potentio meter Y-3
RE1 2 Resistor V-9
AISS M 6 AISS switch (if equipped) P-4 CN5 DT 2 Injector # 5 AL-9 HSL DT2 4 Intermediate connector Y-3
RE3 2 Resistor (female) S-8
ARC M 3 ARSC set switch S-8 CN6 DT2 2 1st Clutch ECMV AF-9 HSOL DT2 2 Hoist selector valve M-5
RE4 2 Resistor (female) S-8
ARSC M 6 ARSC system switch Q-3 CN6 DT 2 Injector # 6 AM-9 HTA DT2 12 Intermediate connector M-6
RES DT2 2 Resisto
AS1 DT2 6 Accel sensor Q-2 CN7 DT2 2 1st Fill switch AF-9 HTB DT2 8 Intermediate connector M-6
RESW DT2 3 Retarder switch
AS2 DT2 2 Intermediate connector R-2 CN8 DT2 2 2nd Clutch ECMV AF-9 INJ DT2 12 Connector AM-7
REVR DT2 2 Retarder valve
AS3 DT2 3 Pitch angle sensor CN9 DT2 2 2nd Fill switch AE-9 J01 HD 9 Intermediate connector J-2
RL M 2 Room lamp F-9
ASR M 6 ASR system switch R-2 CNS1 DT2D 12 Intermediate connector V-1 J02 DRC 70 Intermediate connector I-1
RL2 2 Room lamp 2 H-9
ASR1 3 Steering angle sensor CNS2 DT2C 12 Intermediate connector V-1 J03 DRC 70 Intermediate connector I-1
RLY Terminal 1 Heater relay C-9
ASR2 2 Shut-off solenoid N-2 CNS3 DT2B 12 Intermediate connector V-1 J04 DRC 70 Intermediate connector
RP DT2 8 Intermediate connector B-4
ASR3 2 ASR valve (right) M-3 CUTF 5 ABS Cut valve relay (front) J05 DRC 70 Intermediate connector
RTL DT2 6 Retarder lever potention meter S-8
ASR4 2 ASR valve (left) M-3 CUTR 5 ABS Cut valve relay (rear) J06 DT06 4 Intermediate connector H-1
RTR DT2 2 Retarder oil temperature sensor (right) I-9
ASR5 2 ASR oil pressure switch (right) M-3 D01 AMP 2 Diode Z-8 J07 DT2B 12 Intermediate connector L-9
S01 DT2 2 Service brake switch C-7
ASR6 2 ASR oil pressure switch (left) M-2 D02 AMP 2 Diode Z-8 J08 DT2A 12 Intermediate connector M-8
S02 DT2 2 Secondary brake switch F-9
ASR7 2 ASR oil pressure switch (Main) L-1 D03 AMP 2 Diode Z-8 J13 12 Intermediate connector
S03 DT2 2 Front brake cut valve F-9
ASS DT2 2 Air suspention seat W-2 D04 AMP 2 Diode P-6 J1939 DT2 3 Connector
S04 DT2 2 Auto suspension solenoid 1 (if equipped) G-9
ATC1 DRC 24 Transmission controller AD-1 D05 AMP 2 Diode X-8 J2P DRC 50 Engine controller AN-7
S05 DT2 2 Auto suspension solenoid 2 (if equipped) G-9
ATC2 DRC 40 Transmission controller AD-1 D06 AMP 2 Diode J3P DT06 4 Engine controller AM-6
SBS DT2 2 Seat belt switch X-2
ATC3 DRC 40 Transmission controller AD-4 D07 AMP 2 Diode S-2 JASR 6 Joint connector
SDE M 6 Side lamp switch (if equipped) AA-2
ATC6 X 4 Intermediate connector AA-4 D08 AMP 2 Diode Z-8 JB1 Centralized Centralized terminal AJ-8
terminal SF1 DT2 12 Shift lever U-9
B Terminal 1 Starting switch B terminal P-9 D09 AMP 2 Diode
JCA SWP 16 Joint connector AA-5 SF2 DT2 2 Shift lever T-9
B01 DT2 6 Intermediate connector L-9 D10 AMP 2 Diode
JCB SWP 8 Joint connector AA-5 SLL M 2 Side lamp (left) (if equipped) J-2
B02 DT2 6 Turn signal,tail,stop lamp (right) L-8 D11 AMP 2 Diode
JCC SWP 16 Joint connector AA-5 SLR M 2 Side lamp (right) (if equipped) D-8
B03 DT2 6 Turn signal,tail,stop lamp (left) K-9 D12 DT2 2 Diode M-7
JCD SWP 16 Joint connector AA-4 SPA DT2B 12 Intermediate connector M-7
B04 M 2 Back lamp (70W) DL DT2A 12 Intermediate connector AA-6
JCE SWP 8 Joint connector AA-4 SPARE X 4 Intermediate connector
B05 Terminal 1 Back alarm buzzer K-9 DPC1 AMP070 20 Monitor panel S-8
JCF SWP 16 Joint connector SPL 2 Speaker (left) H-9
B06 Terminal 1 Back alarm buzzer K-9 DPC2A AMP070 18 Monitor panel S-1
JRE DT2 8 Joint connector SPR 2 Speaker (right) G-9
B07 DT2 3 Body positioner sensor J-9 DPC2B AMP070 12 Monitor panel S-1
LKO DT2 2 Lever kick-out solenoid Y-3 SR3 X 3 Steering speed sensor AA-7
B1 DT2 2 Lamp G (right) (for payload meter) (if equipped) D-8 DPC3A AMP070 18 Monitor panel S-8
LKO DT2 2 Intermediate connector X-3 ST1 Terminal 1 Emergency steering switch
B10 Terminal 1 Ground M-8 DPC4 AMP070 12 Monitor panel T-1
One-pin ST2 Terminal 1 Emergency steering switch
B1L DT2 2 Lamp G (left) (for payload meter) (if equipped) L-3 DPC6 AMP070 8 Monitor panel R-7 LM1 connector 1 Download box
ST3 Terminal 1 Emergency steering switch
B2 DT2 2 Lamp A (right) (for payload meter) (if equipped) D-7 DPC7 X 4 Monitor panel Q-3 One-pin
LM2 1 Download box ST4 Terminal 1 Emergency steering switch
B2L DT2 2 Lamp A (left) (for payload meter) (if equipped) L-3 DSL 1 Door switch (left) G-1 connector
LP1 DT2 12 Intermediate connector H-1 STR DT2 2 Steering oil temperature sensor (if equipped) K-3
B3 DT2 2 Lamp R (right) (for payload meter) (if equipped) D-7 DSR 1 Door switch (right) D-7
LS 3 Rheostat Z-2 SUFL DT2 3 Suspention oil pressure sensor (front,left) (if equipped) H-1
B3L DT2 2 Lamp R (left) (for payload meter) (if equipped) M-3 DT7 DT2 12 Intermediate connector W-2
MON AMP 4 Intermediate connector SUFR DT2 3 Suspention oil pressure sensor(front,right) (if equipped) C-6
BCVR X 2 BCV Solenoid (right) J-9 DT8 DT2 4 Intermediate connector W-2
NE FRAMATOME 3 Ne sensor AI-2 SURL DT2 3 Suspention oil pressure sensor(rear,left) M-8
BK DT2 12 Intermediate connector G-9 E01 Terminal 1 Alternater R terminal AK-5
OP7 1 Connector P-1 SURR DT2 3 Suspention oil pressure sensor(rear,right) K-9
BLS M 6 Rotary lamp switch AA-1 E02A DT2 2 Intermediate connector AL-1
OPS DT2 2 Operator seat heter W-2 T05 Terminal 1 Ground K-2
BR Terminal 1 Starting switch BR terminal P-8 E02B DT2 2 Intermediate connector AL-1
ORB-A 14 Orbcom controller (if equipped) T1 Terminal 1 Ground AG-9
BRC1 DRC 24 Retarder controller AC-2 E04 DT2 2 Engine oil level switch AL-5
ORB-B 10 Orbcom controller (if equipped) T10 Terminal 1 Ground B-4
BRC2 DRC 40 Retarder controller AC-2 E05 Terminal 1 Oil filter switch D-2
PAMB AMP 3 Ambient pressure sensor AN-7 T20 Terminal 1 Ground
BRC3 DRC 40 Retarder controller AC-4 E06 Terminal 1 Alternater E terminal AK-5
PCV1 SUMITOMO 2 Supply pump control valve AN-8 TCHET X 4 Intermediate connector
BRC6 X 4 Intermediate connector V-9 E07 X 2 Air compreser
PCV2 SUMITOMO 2 Supply pump control valve AN-8 TEST 1 Connector
BT DT2B 8 Intermediate connector D-9 E09 Terminal 1 Altetnater B terminal AK-5
PDL 5 Download box TFUEL PACKARD 2 Fuel temperature sensor AJ-5
BT1 Fuse box AA-5 E11B Terminal 1 Heater relay D-9
PFUEL AMP 3 Common rail pressure sensor AK-9 TIM PACKARD 2 Boost temperature sensor AN-8
BT-1A Terminal 1 Battery1 (+) E12B Terminal 1 Heater relay D-9
PIM SUMITOMO 3 Boost pressure sensor AN-8 TM2 HD 23 Intermediate connector AH-8
BT-1B Terminal 1 Battery1 (-) E14 Terminal 1 Starting motor B terminal AK-1
PL01 M 2 Head lamp (Hi) (left) F-1 TM3 HD 31 Intermediate connector AH-8
BT2 Fuse box AA-7 E15 Terminal 1 Ground D-2
PL02 M 2 Head lamp (Lo) (right) E-1 TMF1 DT2 2 Transmission oil filter switch
BT-2A Terminal 1 Battery2 (-) E16B Terminal 1 Ground D-9
PL03 M 3 Flont combination lamp (left) F-1 TOIL PACKARD 2 Engine oil temperature sensor AM-6
BT-2B Terminal 1 Battery2 (+) E16E Terminal 1 Ground D-9
One-pin TWTR PACKARD 2 Engine coolant temperature sensor AI-2
BT3 Fuse box AA-6 E17B DT2 2 Diode C-9 PL04 1 Beacon lamp (left) (if equipped) E-1
connector VDL 5 Download box
BT4 Fuse box AA-6 E80 Terminal 1 Ground
PL06 M 2 Fog lamp (left) (if equipped) E-2 VHMS 5 Intermediate connector
BTL DT2 2 Intermediate connector C-7 EG4 DT2D 12 Intermediate connector Y-9
PL07 Terminal 1 Ground C-2 WFM 6 Wiper motor (front) T-1
BZ2 M 2 Buzzer U-1 EM 6 Emergency steering timer
PLM 5 Intermediate connector WFR 6 Wiper relay (front) U-1
C Terminal 1 Starting switch C terminal P-9 EMPR 2 Emergency steering Fuse C-9
PM1 MIC 21 Intermediate connector W-9 WPS DT2B 12 Wiper switch T-8
CAB1 DT2A 8 Intermediate connector T-9 ENG DRC 60 Engine controller AN-6
PM11 MIC 20 Intermediate connector Y-9 WSR 4 Intermediate connector
CAB2 DT2B 8 Intermediate connector T-9 EP 2 Electric priming pump
PM3 DT2 3 Pitch angle sensor AA-7 WSRL 2 Wheel rotation sensor (left) M-1
CAN1 DT2 3 Intermediate connector W-9 EPF 2 Fuse (20A) D-8
PM4 S 16 Intermediate connector W-9 WSRR 2 Wheel rotation sensor (right) M-1
CAN2 DT2 3 Resistor T-1 EPTS 6 Electric priming pump timer switch D-2
PM5 13 Payload meter controller (if equipped) W-9
CAN2 3 Terminal resistor (120 z) I-9 ER Terminal 1 Ground H-9 aDetails of colored connectors
PM6 12 Payload meter controller (if equipped) X-9
CG1 2 Cigarette lighter P-5 ER1 Terminal 1 Ground S-1 DT2A:Gr (Gray), DT2B:B (Black), DT2C:G (Green), DT2D:Br (Brown)
PM7 9 Payload meter controller (if equipped) Q-6
CH1 M 8 Mode selector switch 1 Z-1 ER1 Terminal 1 Ground
PM8 5 Intermediate connector Q-7
CH2 M 8 Mode selector switch 2 Z-1 ER2 Terminal 1 Ground AA-6
PMLA DT2A 12 Intermediate connector H-9
CHECK M 6 ABS Check switch ER3 Terminal 1 Ground R-2
PMRA DT2 6 Intermediate connector E-8
CJA DT2 6 Joint connector C-7 FBC M 6 Front brake cut switch Q-3
POIL FRAMATOME 3 Engine oil pressure sensor AL-5
CJB DT2 6 Joint connector B-6 FL02 DT2 2 Radiator coolant level sensor C-3
PR01 M 2 Head lamp (Lo) (right) B-5
CJC DT2 6 Joint connector B-6 FL04 2 Washer moter C-3
PR02 M 2 Head lamp (Hi) (right) B-4
SEN02314-01
HD465-7R, HD605-7R 7
HD465-7R, HD605-7R 9

© 2007 KOMATSU
All Rights Reserved
10 HD465-7R, HD605-7R

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SEN02283-01

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02283-01

00 Index and foreword SEN02284-01

10 Structure, function and maintenance standard SEN02290-00

20 Standard value table SEN02308-00

30 Testing and adjusting SEN02309-00

Troubleshooting by failure code, Part 1 SEN02533-00 Q

90 Diagrams and drawings SEN02312-01

Foreword and general information SEN02286-00

10 Structure, function and maintenance standard

Accumulator charge valve........................................................................................................... 10

20 Standard value table

30 Testing and adjusting

Releasing residual pressure from fuel system ............................................................................ 19

T-adapter box and T-adapter table .............................................................................................. 37

Failure code [CA123] (Charge pressure sensor low error).......................................................... 10

Troubleshooting by failure code, Part 5 SEN02537-00

Troubleshooting by failure code, Part 6 SEN02538-00

Failure code [DW72KZ] (Kick-out solenoid output system trouble:

Troubleshooting of engine (S-mode) SEN02544-00

90 Diagrams and drawings

HD465-7R, HD605-7R Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips