HD465-7E0 Shop Manual PDF

SEN01081-12
DUMP TRUCK HD465 -7E0

HD605 -7E0
HD465- 10001-10037
HD465- 10101 and up
SERIAL NUMBERS
HD605- 8001-8032
HD605- 10101 and up
SEN01083-12
DUMP TRUCK 1SHOP MANUAL
HD465-7E0
HD605-7E0
Machine model Serial number

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 4
HD465-7E0, HD605-7E0 1
SEN01083-12 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 SEN01081-12
00 Index and foreword SEN01082-12

Index SEN01083-12 q
Foreword and general information SEN01084-06
01 Specification SEN01085-03
Specification and technical data SEN01086-03
10 Structure, function and maintenance standard SEN01087-07

Engine and cooling system SEN01088-02
Power train, Part 1 SEN01089-02
Steering system SEN01091-01
Brake system SEN01092-02
Undercarriage and frame SEN01093-03
Hydraulic system SEN01094-03
Work equipment (Body) SEN04679-00
Cab and its attachments SEN01095-02
Electrical system, Part 1 SEN01096-04
20 Standard value table SEN01100-03

Standard service value table SEN01649-03
30 Testing and adjusting SEN01101-05

Testing and adjusting, Part 1 SEN01650-04
Testing and adjusting, Part 5 SEN01654-04 q
40 Troubleshooting SEN01102-05
Failure code table and fuse locations SEN01660-04
2 HD465-7E0, HD605-7E0
General information on troubleshooting SEN01661-05

Troubleshooting by failure code, Part 1 SEN01662-02
Troubleshooting of electrical system (E-mode) SEN01671-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01672-01
Troubleshooting of engine (S-mode) SEN01673-03
50 Disassembly and assembly SEN01103-04

General information on disassembly and assembly SEN02483-03
Body SEN02491-02
Electrical system SEN02493-01
90 Diagrams and drawings SEN01104-08

Hydraulic diagrams and drawings SEN01105-03
Electrical diagrams and drawings SEN01106-06
HD465-7E0, HD605-7E0 3
Table of contents 1
00 Index and foreword
Index SEN01083-12
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01084-06

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
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 SEN01086-03
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 12
Fuel, coolant and lubricants ........................................................................................................ 13
10 Structure, function and maintenance standard

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 column........................................................................................................................... 2
Steering linkage........................................................................................................................... 3
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Secondary brake valve................................................................................................................ 7
Relay valve.................................................................................................................................. 8
4 HD465-7E0, HD605-7E0
Front brake off valve ................................................................................................................... 9

Accumulator charge valve........................................................................................................... 10
Accumulator ................................................................................................................................ 14
Slack adjuster.............................................................................................................................. 15
Brake........................................................................................................................................... 17
Parking brake solenoid valve ...................................................................................................... 21
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 4
Rear axle support........................................................................................................................ 12
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
Dump control valve (EPC valve) ................................................................................................. 24
Hoist cylinder............................................................................................................................... 28
Hydraulic pump ........................................................................................................................... 29
Work equipment (Body) SEN04679-00
Auto greasing system.................................................................................................................. 2
ROPS cab ................................................................................................................................... 2
Air conditioner ............................................................................................................................. 3
Rear view monitor ....................................................................................................................... 9
Machine monitor system ............................................................................................................. 2
Automatic shift control system .................................................................................................... 2
Transmission controller ............................................................................................................... 6
Automatic emergency steering system ....................................................................................... 20
Automatic suspension system..................................................................................................... 24
Retarder control system .............................................................................................................. 27
Battery disconnector switch ........................................................................................................ 38
Dump control lever ...................................................................................................................... 44
Payload meter (Card type) ...................................................................................................... 2
VHMS controller related .............................................................................................................. 2
ASR system (If equipped) ........................................................................................................... 26
Sensors, switches ....................................................................................................................... 32
20 Standard value table
Standard service value table SEN01649-03
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 4
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Sketch of special tool .................................................................................................................. 9
Testing engine speed .................................................................................................................. 10
HD465-7E0, HD605-7E0 5
Testing air supply pressure (boost pressure) .............................................................................. 11

Testing exhaust temperature ....................................................................................................... 12
Testing exhaust gas color............................................................................................................ 14
Adjustment of valve clearance .................................................................................................... 16
Testing of compression pressure................................................................................................. 18
Testing blow-by pressure............................................................................................................. 21
Testing engine oil pressure.......................................................................................................... 22
Testing EGR valve and bypass valve drive oil pressure.............................................................. 23
Handling of fuel system devices.................................................................................................. 25
Releasing residual pressure from fuel system ............................................................................ 25
Testing of fuel pressure ............................................................................................................... 26
Reduced cylinder mode operation............................................................................................... 27
No-injection cranking................................................................................................................... 27
Testing of fuel return rate and fuel leakage ................................................................................. 28
Bleeding air from fuel circuit ........................................................................................................ 30
Testing the fuel circuit for leakage ............................................................................................... 31
Replacement and adjustment of fan belt..................................................................................... 32
Replacement and adjustment of alternator and air conditioner compressor belt ........................ 33
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.......................................................................................................... 19
Bleeding air from brake circuit..................................................................................................... 21
Testing wear of front brake pad ................................................................................................... 22
Testing wear of rear brake disc ................................................................................................... 23
Method of releasing parking brake in an emergency .................................................................. 24
Testing and adjusting front suspension cylinder.......................................................................... 25
Testing and adjusting rear suspension cylinder........................................................................... 29
Testing and adjusting front suspension cylinder (Automatic suspension specification) .............. 33
Testing and adjusting hydraulic pressure in steering, hoist circuit............................................... 34
Testing and adjusting oil pressure in dump EPC circuit .............................................................. 37
Air bleeding from steering cylinder .............................................................................................. 38
Procedure for raising dump body in emergency.......................................................................... 39
Procedure for lowering dump body in emergency....................................................................... 40
Adjusting body positioner sensor ................................................................................................ 42
Handling of voltage circuit of engine controller............................................................................ 43
Adjusting transmission controller................................................................................................. 43
Method for emergency escape at electrical system failure ......................................................... 44
Setting and adjusting of devices.................................................................................................. 2
Special functions of machine monitor (EMMS)............................................................................ 14
Special functions of machine monitor (EMMS)............................................................................ 2
Request for opening ORBCOMM terminal .................................................................................. 2
VHMS controller initial setting procedure .................................................................................... 4
Using method of KOMTRAX functions of ORBCOMM terminal .................................................. 24
Precautions for replacing VHMS controller ................................................................................. 27
Pm Clinic check sheet ................................................................................................................. 33
Initial setting of payload meter..................................................................................................... 37
Setting of payload meter built in VHMS....................................................................................... 38
Setting of card-type payload meter (PLM- ) after installation or replacement ........................... 46
6 HD465-7E0, HD605-7E0
40 Troubleshooting
General information on troubleshooting SEN01661-05
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-branch box and T-branch adapter table ................................................................................... 44
Failure code table and fuse locations SEN01660-04
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 13
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] Trouble in 2nd clutch pressure control valve
(Fill signal is ON though command current is OFF) ............................................................. 3
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve (Though command
is holding pressure, 2nd clutch fill switch is OFF, and slipping detected) ............................ 6
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve (Though command
is holding pressure, 3rd clutch fill switch is OFF, and slipping detected) ............................. 12
Failure code [15SHL1] Trouble in 4th clutch pressure control valve
Failure code [15SHMA] Trouble in 4th clutch pressure control valve (Though command
is holding pressure, 4th clutch fill switch is OFF, and slipping detected) ............................. 18
Failure code [15SJMA] Trouble in lockup clutch pressure control valve
(Though lockup command is holding pressure, slipping is detected) .................................. 20
Failure code [2C4MNX] Retarder cooling oil filter: Clogging ....................................................... 22
Failure code [2F00KM] Parking brake: Dragging ........................................................................ 24
Failure code [2G42ZG] Lowering of accumulator oil pressure (Front) ........................................ 27
Failure code [2G43ZG] Lowering of accumulator oil pressure (Rear)......................................... 27
Failure code [6014NX] Hydraulic oil filter: Clogging.................................................................... 28
Failure code [989A00] Operation of engine overrun prevention device (Note: Information
is obtained from transmission controller and failure code is displayed on monitor panel) ... 30
HD465-7E0, HD605-7E0 7
Failure code [989D00] Inclination alarm (Raising body while machine is inclined)
(Note: Information is obtained from transmission controller
and failure code is displayed on monitor panel) ................................................................... 30
Failure code [A570NX] Engine oil filter: Clogging ....................................................................... 31
Failure code [AA10NX] Air cleaner: Clogging ............................................................................. 32
Failure code [AB00MA] Trouble in battery charge circuit
(No R-terminal signal from alternator).................................................................................. 34
Failure code [B@BAZG] Lowering of engine oil pressure........................................................... 36
Failure code [B@BAZK] Lowering of engine oil .......................................................................... 38
Failure code [B@BCNS] Engine overheat .................................................................................. 40
Failure code [B@BCZK] Coolant level low alarm........................................................................ 42
Failure code [B@BFZK] Lowering of fuel level............................................................................ 44
Failure code [B@C7NS] Overheating of brake cooling oil (Rear) ............................................... 46
Failure code [B@CENS] Overheating of torque converter oil ..................................................... 48
Failure code [B@GAZK] Lowering of battery electrolyte level .................................................... 49
Failure code [B@JANS] Overheating of steering oil ................................................................... 50
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........................................................................... 15
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 system disconnection or short circuit...................................... 54
Failure code [CA342] Engine controller data 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] Idle validation switch error ........................................................................ 4
Failure code [CA432] Idle validation action error ........................................................................ 8
Failure code [CA441] Battery voltage low error........................................................................... 8
8 HD465-7E0, HD605-7E0
Failure code [CA442] Battery voltage high error ......................................................................... 9

Failure code [CA449] Common rail pressure high error 2........................................................... 9
Failure code [CA451] Common rail pressure sensor high error.................................................. 10
Failure code [CA452] Common rail pressure sensor low error ................................................... 12
Failure code [CA553] Common rail pressure high error 1........................................................... 13
Failure code [CA554] Common rail pressure sensor: In-range error .......................................... 14
Failure code [CA559] Supply pump no-pressure feed error 1..................................................... 15
Failure code [CA689] Engine Ne speed sensor error ................................................................. 18
Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 20
Failure code [CA757] All engine controller data lost error........................................................... 21
Failure code [CA778] Engine Bkup speed sensor error .............................................................. 22
Failure code [CA1228] EGR valve servo error 1......................................................................... 24
Failure code [CA1625] EGR valve servo error 2......................................................................... 25
Failure code [CA1626] Short circuit in bypass valve solenoid drive system ............................... 26
Failure code [CA1627] Disconnection in bypass valve solenoid drive system............................ 28
Failure code [CA1628] Bypass valve servo error 1 ..................................................................... 29
Failure code [CA1629] Bypass valve servo error 2 ..................................................................... 30
Failure code [CA1631] Bypass valve lift sensor high error.......................................................... 32
Failure code [CA1632] Bypass valve lift sensor low error ........................................................... 34
Failure code [CA1633] KOMNET (datalink timeout) error ........................................................... 35
Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 36
Failure code [CA2186] Throttle sensor power supply low error .................................................. 38
Failure code [CA2249] Supply pump no-pressure feed error 2................................................... 39
Failure code [CA2271] EGR valve lift sensor high error ............................................................. 40
Failure code [CA2272] EGR valve lift sensor low error ............................................................... 42
Failure code [CA2351] Short circuit in EGR valve solenoid drive system ................................... 44
Failure code [CA2352] Disconnection in EGR valve solenoid drive system ............................... 46
Failure code [CA2555] Intake heater relay voltage low error ...................................................... 47
Failure code [CA2556] Intake heater relay voltage high error..................................................... 48
Failure code [D19HKB] Short circuit in stop lamp relay output system....................................... 3
Failure code [D5ZKKZ] Trouble in front brake cut valve system
(Disconnection or short circuit) ............................................................................................ 4
Failure code [DAF9KM] Wrong connection of connector ............................................................ 6
Failure code [DAFRKR] Abnormal CAN communication (machine monitor) .............................. 8
Failure code [DAQ0KK] Lowering of power supply voltage in transmission controller
direct power supply .............................................................................................................. 10
Failure code [DAQ0KT] Abnormality in transmission controller nonvolatile memory .................. 12
Failure code [DAQ2KK] Transmission controller solenoid power supply voltage low error......... 13
Failure code [DAQ9KQ] Disagreement of model selection signal (Transmission controller) ...... 14
Failure code [DAQRKR] Abnormality in CAN communication (Transmission controller) ............ 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ................... 15
Failure code [DB10KT] Abnormality in retarder controller nonvolatile memory........................... 15
Failure code [DB12KK] Trouble in retarder controller solenoid power supply system ................ 16
Failure code [DB13KK] Retarder controller battery direct power supply voltage low error ......... 18
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 20
Failure code [DB1RKR] Abnormality in CAN communication (Retarder controller) .................... 22
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)............................ 24
Failure code [DB2RKR] Abnormality in CAN communication (Engine controller) ....................... 26
Failure code [DBB0KK] (or VHMS_LED display: “n9” o “01”)
VHMS controller: Low source voltage (input)....................................................................... 30
Failure code [DBB0KQ] (or VHMS_LED display: “nF” o “11”)
(VHMS controller: Disagreement of model selection signals) .............................................. 32
VHMS controller battery power supply: Low source voltage (input) .................................... 33
Failure code [DBB5KP] (or VHMS_LED display: “n9” o “04”)
(VHMS controller 5 V power supply output: Low output voltage)......................................... 36
HD465-7E0, HD605-7E0 9

(VHMS controller 24 V power supply output: Low output voltage) ....................................... 38
(VHMS controller 12 V power supply output: Low output voltage) ....................................... 40
Failure code [DBBQKR] (or VHMS_LED display: “n8” o “02”)
VHMS controller CAN communication: Defective communication
(Abnormality in target component system)........................................................................... 42
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ....................................... 45
Failure code [DBC2KK] Trouble in ABS controller solenoid power supply system ..................... 46
Failure code [DBC3KK] ABS controller battery direct power supply voltage low error................ 48
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) ............................... 50
Failure code [DBCRKR] Abnormality in CAN communication (ABS controller) .......................... 50
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................. 51
Failure code [DDD7KX] Trouble in travel speed setting switch system
(If equipped) (When ARSC is set and ARSC system switch is ON) .................................... 52
Failure code [DDD8KA] Disconnection in ARSC system switch
Failure code [DDD8KB] Short circuit in ARSC system switch
Failure code [DDD9KA] Disconnection in ABS system switch
(When ABS is set and ABS system switch is ON) ............................................................... 58
Failure code [DDD9KB] Short circuit in ABS system switch
(When ABS is set and ABS system switch is ON) ............................................................... 60
Failure code [DDDAKA] Disconnection in ASR system switch ................................................... 62
Failure code [DDDAKB] Short circuit in ASR system switch ....................................................... 64
Failure code [DDP6L4] Trouble in service brake pressure switch (Rear).................................... 66
Failure code [DDTHKA] Trouble in Hi clutch fill switch
(Command is holding pressure, fill switch is OFF, and slip is not sensed)........................... 68
Failure code [DDTJKA] Trouble in Lo clutch fill switch
Failure code [DDTKKA] Trouble in 1st clutch fill switch
Failure code [DDTLKA] Trouble in 2nd clutch fill switch
Failure code [DDTMKA] Trouble in 3rd clutch fill switch
Failure code [DDTNKA] Trouble in R clutch fill switch
Failure code [DDTPKA] Trouble in 4th clutch fill switch
(Command is holding pressure, fill switch is OFF, and slip is not sensed).......................... 80
Failure code [DF10KA] Gear shift lever signal non-input ............................................................ 82
Failure code [DF10KB] Gear shift lever signal multi-input........................................................... 85
Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”)
(Atmospheric temperature sensor: Out of input signal range) ............................................. 88
Failure code [DGF1KX] Transmission oil temperature sensor input signal out of range............. 90
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor rear wheel system
(Ground fault) ....................................................................................................................... 92
Failure code [DGR6KX] Steering oil temperature sensor input signal out of range .................... 94
Failure code [DGT1KX] Torque converter oil temperature sensor input signal out of range ....... 96
Failure code [DGT4KA] (or VHMS_LED display: “n3” o “12”)
(Exhaust gas temperature sensor (F): Disconnection)......................................................... 4
Failure code [DGT4KB] (or VHMS_LED display: “n3” o “11”)
(Exhaust gas temperature sensor (F): Short circuit) ............................................................ 6
(Exhaust gas temperature sensor (R): Disconnection) ........................................................ 8
(Exhaust gas temperature sensor (R): Short circuit)............................................................ 10
10 HD465-7E0, HD605-7E0
Failure code [DHE5KB] (or VHMS_LED display: “n3” o “32”)

(Blow-by pressure sensor: Short circuit) .............................................................................. 12
Failure code [DHE5KY] (or VHMS_LED display: “n3” o “31”)
(Blow-by pressure sensor: Short circuit with power supply line) .......................................... 14
Failure code [DHP4KY] (or VHMS_LED display: “n5” o “44”)
Short circuit in suspension pressure sensor system (Front right) ........................................ 16
Failure code [DHP4KZ] (or VHMS_LED display: “n5” o “43”)
Disconnection or ground fault in suspension pressure sensor system (Front right) ............ 18
Short circuit in suspension pressure sensor system (Front left) .......................................... 20
Disconnection or ground fault in suspension pressure sensor system (Front left)............... 22
Failure code [DHP6KA] Trouble in suspension pressure sensor system (Right rear)................. 24
Failure code [DHP6KX] Trouble in suspension pressure sensor system (Right rear)................. 26
Short circuit in suspension pressure sensor system (Right rear)......................................... 28
Disconnection or ground fault in suspension pressure sensor system (Right rear) ............. 30
Failure code [DHP7KA] Trouble in suspension pressure sensor system (Left rear) ................... 32
Failure code [DHP7KX] Trouble in suspension pressure sensor system (Left rear) ................... 34
Short circuit in suspension pressure sensor system (Left rear) ........................................... 36
Disconnection or ground fault in suspension pressure sensor system (Left rear) ............... 38
Failure code [DHT5KX] Disconnection, ground fault in torque converter
inlet oil pressure sensor ....................................................................................................... 40
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor..................................... 42
Failure code [DHU2KX] Trouble in front accumulator oil pressure sensor.................................. 44
Failure code [DHU3KX] Trouble in rear accumulator oil pressure sensor................................... 46
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................. 48
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) .................... 50
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)................... 52
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left) ..................... 54
Failure code [DJF1KA] Disconnection in fuel level sensor.......................................................... 56
Failure code [DK30KX] Trouble in steering angle potentiometer ................................................ 57
Failure code [DK51L5] Trouble in manual retarder potentiometer and retarder swich signal ..... 58
Failure code [DK52KX] Trouble 1 in hoist lever potentiometer sensor........................................ 62
Failure code [DK53L8] Trouble 2 in hoist lever potentiometer sensor ........................................ 64
Failure code [DK54KX] Trouble in body positioner sensor.......................................................... 66
Failure code [DKD0L6] Trouble in steering speed sensor........................................................... 68
Failure code [DKH0KX] Clinometer sensor signal out of range .................................................. 70
Failure code [DKH1KX] (or VHMS_LED display: “n4” o “33”)
Abnormality in clinometer sensor......................................................................................... 72
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system........... 74
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................. 76
Failure code [DLF2KA] Disconnection in transmission intermediate shaft
speed sensor system ........................................................................................................... 78
Failure code [DLF2LC] Trouble in transmission intermediate shaft speed sensor ...................... 80
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)................................ 3
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) ........................................... 4
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) .................................. 5
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................. 6
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) ................................ 8
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)............................................ 10
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)............................... 12
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)................................ 13
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)................................... 14
HD465-7E0, HD605-7E0 11
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear) .............................................. 16
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) ................................. 18
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear) .................................. 19
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system ......... 20
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor ................................ 22
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor ..................... 24
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor..................... 26
Failure code [DV00KB] Short circuit in buzzer output ................................................................. 28
Failure code [DW2AKA] Disconnection in main pressure variable valve output ......................... 30
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit.................. 32
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit....................... 34
Failure code [DW2AL1] Defective reset of main pressure variable valve ................................... 36
Failure code [DW2ALH] Malfunction of main pressure variable valve ........................................ 38
Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1
(Disconnection or short circuit)............................................................................................. 40
Failure code [DW72KZ] Trouble in kick-out solenoid output system
Failure code [DW73KZ] Trouble in hoist select valve output system
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) ........................ 50
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit .............................. 52
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit ................................. 54
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit .................................. 56
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) ..................... 57
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system ........................................ 58
Failure code [DWNDMA] Defective ABS cut-off valve (Front)..................................................... 60
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system ......................................... 62
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ..................................................... 64
Failure code [DX11K4] Trouble in rear brake proportional pressure reducing
solenoid valve (Valve keeps operating)................................................................................ 4
Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing
solenoid valve output circuit ................................................................................................. 6
Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing
solenoid valve ...................................................................................................................... 7
Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing
solenoid valve output circuit ................................................................................................. 8
Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing
solenoid valve (Valve does not operate) .............................................................................. 9
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit..................................... 10
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit ........................................ 12
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit ........................................ 14
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve
(right) (Valve keeps operating) ............................................................................................. 16
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve
(right) output circuit .............................................................................................................. 18
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve
(right) (Valve does not operate)............................................................................................ 22
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve
(left) (Valve keeps operating) ............................................................................................... 24
12 HD465-7E0, HD605-7E0
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve
(left) output circuit ................................................................................................................ 26
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve
(left) (Valve does not operate).............................................................................................. 30
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).............. 31
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) ................ 32
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...................... 33
Failure code [DX21MA] Defective ABS control valve (Front right) .............................................. 34
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) ................ 35
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)................... 36
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) ........................ 37
Failure code [DX22MA] Defective ABS control valve (Front left) ................................................ 38
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) .............. 39
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................. 40
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ...................... 41
Failure code [DX23MA] Defective ABS control valve (Rear right) .............................................. 42
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)................. 43
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ................... 44
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)......................... 45
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................. 46
Failure code [DX25MA] Defective ABS front wheel system control valve................................... 47
Failure code [DX26MA] Defective ABS rear wheel system control valve ................................... 47
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ......................... 3
Failure code [DXH1KB] (Lock-up 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:
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: 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:
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”)
(Blow-by pressure: High error)............................................................................................. 60
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”)
(Exhaust gas temperature (F): Abnormal heat) ................................................................... 62
HD465-7E0, HD605-7E0 13
Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”)

(Exhaust gas temperature (F): Overheat) ............................................................................ 64
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat).................................................................... 66
Failure code [F@BZNS] (or VHMS_LED display “n3” o “71”)
(Exhaust gas temperature (R): Overheat)............................................................................ 68
Troubleshooting of electrical system (E-mode) SEN01671-03
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 Alarm buzzer does not stop sounding .................................................................................. 18
E-7 Gauges of machine monitor, caution lamps or character display
section do not display properly............................................................................................. 20
E-8 A selection of the display in character display section cannot be changed .......................... 21
E-9 Power mode selecting function does not operate properly................................................... 24
E-10 AISS function does not operate properly ............................................................................ 25
E-11 Seat belt caution lamp does not display properly ............................................................... 26
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly................................ 27
E-13 Night illumination (lighting) does not work properly ............................................................ 30
E-14 Emergency steering does not operate................................................................................ 42
E-15 Hoist lever does not operate normally ................................................................................ 48
E-16 Electric priming pump does not operate or does not stop automatically ............................ 50
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01672-01
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
Troubleshooting of engine (S-mode) SEN01673-03
Method of using troubleshooting chart ........................................................................................ 4
S-1 Starting performance of engine is poor................................................................................. 8
S-2 Engine does not start............................................................................................................ 10
S-3 Engine does not pick up smoothly ........................................................................................ 14
S-4 Engine stops during operation .............................................................................................. 15
S-5 Engine does not rotate smoothly .......................................................................................... 16
S-6 Engine lack output (or lacks power)...................................................................................... 17
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 18
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20
S-9 Oil becomes dirty quickly ...................................................................................................... 21
S-10 Fuel consumption is excessive ........................................................................................... 22
14 HD465-7E0, HD605-7E0
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 23
S-12 Oil pressure drops .............................................................................................................. 24
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 26
S-14 Coolant temperature becomes too high (Overheating) ...................................................... 28
S-15 Abnormal noise is made ..................................................................................................... 29
S-16 Vibration is excessive ......................................................................................................... 30
S-17 Air cannot be bled from fuel circuit ..................................................................................... 32
50 Disassembly and assembly

General information on disassembly and assembly SEN02483-03
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 10
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 5
Removal and installation of cylinder head assembly .................................................................. 9
Removal and installation of engine front seal ............................................................................. 21
Removal and installation of engine rear seal .............................................................................. 24
Removal and installation of engine assembly ............................................................................. 28
Removal and installation of radiator assembly............................................................................ 35
Removal and installation of output shaft assembly ..................................................................... 39
Disassembly and assembly of output shaft assembly................................................................. 40
Removal and installation of brake and power train oil cooler assembly...................................... 43
Removal and installation of torque converter and transmission assembly ................................. 2
Separation and coupling of transmission assembly and torque converter assembly.................. 5
Disassembly and assembly of transmission assembly and torque converter assembly ............. 6
Disassembly and assembly of torque converter assembly ......................................................... 8
Disassembly and assembly of transmission assembly ............................................................... 18
Removal and installation of transmission control valve assembly (ECMV assembly)................. 49
Disassembly and assembly of transmission control valve assembly (ECMV assembly) ............ 50
Removal and installation of differential assembly ....................................................................... 2
Disassembly and assembly of differential assembly ................................................................... 4
Removal and installation of final drive carrier assembly ............................................................. 16
Disassembly and assembly of final drive carrier assembly......................................................... 17
Disassembly and assembly of front wheel hub assembly........................................................... 18
Disassembly and assembly of steering cylinder assembly ......................................................... 2
Removal and installation of front brake caliper pads................................................................... 2
Removal and installation of front brake calipers assembly ......................................................... 3
Disassembly and assembly of front brake calipers assembly ..................................................... 4
Removal and installation of final drive and rear brake assembly ................................................ 6
Removal and installation of final drive, rear brake, and parking brake assembly ....................... 9
Disassembly and assembly of final drive, rear brake, and parking brake assembly ................... 10
Removal and installation of front wheel assembly ...................................................................... 2
Removal and installation of rear wheel assembly ....................................................................... 4
Removal and installation of front suspension cylinder assembly ................................................ 6
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)... 8
Removal and installation of rear suspension cylinder assembly ................................................. 11
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) ... 12
HD465-7E0, HD605-7E0 15

Disassembly and assembly of hoist cylinder assembly............................................................... 2
Body SEN02491-02
Removal and installation of body assembly ................................................................................ 2
Disassembly and assembly of operator's seat assembly ............................................................ 2
Removal and installation of air conditioner unit assembly........................................................... 11
Electrical system SEN02493-01
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of transmission controller assembly .................................................... 3
Removal and installation of retarder controller assembly............................................................ 4
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01105-03
Power train hydraulic circuit diagram .......................................................................................... 2
Steering and hoist hydraulic circuit diagram................................................................................ 3
Brake hydraulic circuit diagram ................................................................................................... 7
Electrical diagrams and drawings SEN01106-06
Electrical circuit diagram inside cab (1/3).................................................................................... 3
Electrical circuit diagram outside cab (1/3).................................................................................. 9
Electrical circuit diagram for VHMS............................................................................................. 15
Electrical circuit diagram for ASR (If equipped)........................................................................... 17
Air conditioner electrical circuit diagram...................................................................................... 19
Electrical circuit diagram for auto greasing (If equipped) ............................................................ 21
Connectors table and arrangement drawing ............................................................................... 23
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
HD465-7E0, HD605-7E0 Dump truck

Form No. SEN01083-12
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (02)
18 HD465-7E0, HD605-7E0
SEN01084-06
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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 of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
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
HD465-7E0, HD605-7E0 1
Safety notice 1
(Rev. 2008/08)
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. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 HD465-7E0, HD605-7E0
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. 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
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
HD465-7E0, HD605-7E0 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 well seen
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 HD465-7E0, HD605-7E0
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
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
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.
HD465-7E0, HD605-7E0 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
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,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
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
HD465-7E0, HD605-7E0 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 or allow-

able dimension
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, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
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 HD465-7E0, HD605-7E0
Handling of 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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 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 HD465-7E0, HD605-7E0
3. Push lock type

q 95, 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 engines

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.
HD465-7E0, HD605-7E0 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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 – – – – – – –
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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-
HD465-7E0, HD605-7E0 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.
a The following table applies 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 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
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 applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 HD465-7E0, HD605-7E0
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}
HD465-7E0, HD605-7E0 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. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
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 face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. 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 — —
34 HD465-7E0, HD605-7E0
8. 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
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41

© 2008 KOMATSU
All Rights Reserved
42 HD465-7E0, HD605-7E0
SEN01086-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
01 Specification 1
Specification and technical data
Specification drawing ...................................................................................................................................... 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................. 12
Fuel, coolant and lubricants .......................................................................................................................... 13
HD465-7E0, HD605-7E0 1
SEN01086-03 01 Specification
Specification drawing 1
HD465-7E0
HD605-7E0
2 HD465-7E0, HD605-7E0
q For EU (Stairway specifications)
HD465-7E0
HD605-7E0
HD465-7E0, HD605-7E0 3
Specifications 1
Machine model HD465-7E0
Serial No. 10001 – 10037, 10101 and up
Empty kg 43,180
Max. load kg 55,000
Gross kg 98,180
Weight
(front) kg 20,295 (47%)

Empty
distribution
(rear) kg 22,885 (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} 200 {149}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 2 units
4 HD465-7E0, HD605-7E0
Machine model HD465-7E0 For EU (Stairway specifications)
Serial No. 10101 and up
Empty kg 43,460
Max. load kg 54,640
Gross kg 98,180
Weight
(front) kg 20,560 (47%)

Empty
distribution
(rear) kg 22,900 (53%)

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

Gross
(rear) kg 66,760 (68%)
Struck m3 25
Dump body capacity
Heaped (2 :1) m3 34.2
Performance
Dumping angle ° 48

Dimensions
Wheel base mm 4,300

Tread
Rear wheel mm 3,080


Engine

Alternator 24V, 90A
HD465-7E0, HD605-7E0 5
Serial No. 10001 – 10037, 10101 and up
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
6 HD465-7E0, HD605-7E0
Serial No. 10001 – 10037, 10101 and up
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
HD465-7E0, HD605-7E0 7
Serial No. 8001 – 8032, 10101 and up
Empty kg 46,280
Max. load kg 63,000
Gross kg 109,280
Weight
(front) kg 21,750 (47%)

Empty
distribution
(rear) kg 24,530 (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
Dumping angle ° 48

Dimensions
Wheel base mm 4,300

Tread
Rear wheel mm 3,080

Engine

Alternator 24V, 90A
8 HD465-7E0, HD605-7E0
Machine model HD605-7E0 For EU (Stairway specifications)
Serial No. 10101 and up
Empty kg 46,560
Max. load kg 62,715
Gross kg 109,280
Weight
(front) kg 22,020 (47%)

Empty
distribution
(rear) kg 24,540 (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
Dumping angle ° 48

Dimensions
Wheel base mm 4,300

Tread
Rear wheel mm 3,080

Engine

Alternator 24V, 90A
HD465-7E0, HD605-7E0 9
Serial No. 8001 – 8032, 10101 and up
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
10 HD465-7E0, HD605-7E0
Serial No. 8001 – 8032, 10101 and up
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
HD465-7E0, HD605-7E0 11
Weight table 1
This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model HD465-7E0 HD605-7E0
Serial Number 10001 – 10037, 10101 and up 8001 – 8032, 10101 and up
Engine assembly 3,120 3,120

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
12 HD465-7E0, HD605-7E0
Fuel, coolant and lubricants 1

a Regarding the details of notes (note 1, note 2, …), refer to "Operation and Maintenance Manual".
HD465-7E0, HD605-7E0 13
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
Fuel and oil

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

amount of oil including oil for components and
oil in piping. The refill capacity means the
amount of oil needed to refill the system dur-
ing normal inspection and maintenance.
a When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
engine oil of SAE10W, SAE 10W-30 or
SAE15W-40, even through the atmospheric
temperature goes up to 10°C or above during
the day.
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15

© 2009 KOMATSU
All Rights Reserved
16 HD465-7E0, HD605-7E0
SEN01088-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
HD465-7E0, HD605-7E0 1
SEN01088-02 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
4 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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 –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
HD465-7E0, HD605-7E0 7

© 2007 KOMATSU
All Rights Reserved
8 HD465-7E0, HD605-7E0
SEN01089-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Power train, 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
HD465-7E0, HD605-7E0 1
Power train skeleton 1
2 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5
Torque converter and transmission hydraulic piping 1
6 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 9
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 11
12 HD465-7E0, HD605-7E0
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“
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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}
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 19
20 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 21
22 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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 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)
HD465-7E0, HD605-7E0 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)
28 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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
L ring gear (2) 3rd planetary pinion (17)
O O
H ring gear (5) 3rd, R carrier (18)
O O O
L clutch housing (7) 2nd ring gear (13) 2nd sun gear (11)
O
2nd planetary pinion (12) i i
O
1st, 2nd carrier (10)
O
Output shaft (24)
30 HD465-7E0, HD605-7E0
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
H planetary pinion (6) 3rd planetary pinion (17)
O O
O O O
L clutch housing (7) 2nd ring gear (13) 2nd sun gear (11)
O
O
O
Output shaft (24)
HD465-7E0, HD605-7E0 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
L ring gear (2) 4th clutch drum (19)
O O
H ring gear (5) 4th ring gear (20)
O O
L clutch housing (7) 3rd, R carrier (18)
O O
2nd ring gear (13) 2nd sun gear (11)
O
O
O
Output shaft (24)
32 HD465-7E0, HD605-7E0
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
H planetary pinion (6) 4th clutch drum (19)
O O
H ring gear (5) 4th ring gear (20)
O O
L clutch housing (7) 3rd, R carrier (18)
O O
O
O
O
Output shaft (24)
HD465-7E0, HD605-7E0 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 i
O O
L ring gear (2) R planetary pinion (23) Intermediate shaft (8)
O O I
O (R ring gear (21) is fixed with R
L clutch housing (7) clutch = 3rd, R carrier (18) is
rotated reverse to input shaft (1))
O
O I
2nd planetary pinion (12) o
O
O
Output shaft (24)
34 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43

© 2007 KOMATSU
All Rights Reserved
44 HD465-7E0, HD605-7E0
SEN01090-01
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Power train, Part 2
Axle ................................................................................................................................................................. 2
Differential ....................................................................................................................................................... 4
Final drive ....................................................................................................................................................... 5
Wheels ............................................................................................................................................................ 6
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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 (HD465-7E0)
24.00R35 (HD605-7E0)
Rim size: 17.00-35
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 5
Wheels 1
Front wheel
1. Tire
2. Rim assembly
3. Valve
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7E0)
24.00R35 (HD605-7E0)
Rear wheel
1. Rim assembly
2. Valve
3. Extension
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7E0)
24.00R35 (HD605-7E0)
6 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 7

© 2007 KOMATSU
All Rights Reserved
8 HD465-7E0, HD605-7E0
SEN01091-01
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Steering system
Steering column .............................................................................................................................................. 2
Steering linkage .............................................................................................................................................. 3
HD465-7E0, HD605-7E0 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
2 HD465-7E0, HD605-7E0
Steering linkage 1
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm
HD465-7E0, HD605-7E0 3
4 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 5

© 2007 KOMATSU
All Rights Reserved
6 HD465-7E0, HD605-7E0
SEN01092-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
HD465-7E0, HD605-7E0 1
Brake piping 1
2 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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}
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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. Cylinder (for parking brake)
18 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 21

© 2007 KOMATSU
All Rights Reserved
22 HD465-7E0, HD605-7E0
SEN01093-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 4
Rear axle support.......................................................................................................................................... 12
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 3
Suspension cylinder 1
Front
1. Feed valve A: Port

2. Cylinder B: Port
3. Rod
4. Valve (for bleeding air)
5. Air bleeding valve
6. Tube
4 HD465-7E0, HD605-7E0
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit Replace
8
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
9 160 0.7
and bushing –0.106 +0.360 0.646 bushing
Clearance between cylinder –0.05 +0.115 0.05 – Replace
10 200 0.8
and wear ring –0.26 0 0.375 wear ring
Repair limit
11 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
12 Deformation of stopper Protrusion:
Max. 2 mm
No cracks
HD465-7E0, HD605-7E0 5
Auto suspension specification
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
6 HD465-7E0, HD605-7E0
Unit: mm

11
and bushing bushing
–0.043 +0.240 0.103 –
160 0.4
–0.106 +0.006 0.346
12 160 0.7
and bushing –0.106 +0.360 0.646 bushing
Clearance between cylinder –0.05 +0.115 0.05 – Replace
13 200 0.8
and wear ring –0.26 0 0.375 wear ring
Repair limit
14 Elasticity of leaf spring

Max. 0.3 mm
Replace
Measuring method:
Measure protrusion and elongation of stopper.
All the conditions below must be fulfilled.
Elongation :
Max. 5 mm
15 Deformation of stopper Protrusion:
Max. 2 mm
No cracks
HD465-7E0, HD605-7E0 7
Structure and operation 2. Principle of generation of damping force

The suspension cylinder acts as a shock absorber Inside of valve body (8) are orifice plate (8a)
and spring. The inside of the cylinder is divided into and leaf springs (8b) and (8c). They restrict
gas chamber (A) which is charged with nitrogen the flow of oil between oil chamber (B) and oil
gas, and oil chamber (B) which is filled with oil. Oil chamber (C), and create a damping force.
chamber (B) and oil chamber (C) are conmected by 1) Action when retracting
tube (6) and valve body (8). When the nitrogen gas is compressed by
1. Nitrogen gas the external force from the road surface,
While the machine is traveling, the wheels fol- the oil in oil chamber (B) flows from oil
low the unevenness of the road surface, and chamber (B) through the valve (8) and
an external force in the updown direction is tube (6) to oil chamber (C). The oil flowing
applied to the suspension cylinder. When this through the valve from direction (Y) to ori-
happens, the volume of the nitrogen gas in gas fice plate (8a) is throttled by orifices in four
chamber (A) changes elastically under the places to generate a damping force.
input force, and absorbs the external force. 2) Action when extending
The nitrogen gas is sealed by a rod and oil, so When the external force from the road sur-
it is always subjected to a pressure corre- face gets weak, the pressure of the nitro-
sponding to the external force, and acts as an gen gas extends the rod, and the oil in oil
air spring. chamber (C) passes through tube (6) and
valve (8) and flows to oil chamber (B).
The oil inside the valve flows from direc-
tion (Z) and passes through two orifices
from orifice plate (8a) to generate a damp-
ing force.
8 HD465-7E0, HD605-7E0
3. 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 hydraulic 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.
HD465-7E0, HD605-7E0 9
Rear
1. Feed valve
2. Cylinder
3. Rod
4. Valve (for bleeding air and mounting pressure sensor)
5. Ball
10 HD465-7E0, HD605-7E0
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.
1) 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.
2) 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.
HD465-7E0, HD605-7E0 11
Rear axle support 1
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
12 HD465-7E0, HD605-7E0
Unit: mm
Clearance between rod mount- size Shaft Hole clearance limit
5
ing pin and bushing
–0.030 +0.046 0.030 –
70 0.1
–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
HD465-7E0, HD605-7E0 13

© 2008 KOMATSU
All Rights Reserved
14 HD465-7E0, HD605-7E0
SEN01094-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
Dump control valve (EPC valve) ................................................................................................................... 24
Hoist cylinder ................................................................................................................................................ 28
Hydraulic pump ............................................................................................................................................. 29
HD465-7E0, HD605-7E0 1
Steering and hoist hydraulic piping 1
2 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 3
Dump body control 1
1. Dump control lever Function

2. Hydraulic pump (SDR(30)80+80+SB(1)6) q The positioner sensor senses the body control
3. Hoist valve operation, and from this data the retarder con-
4. Dump control valve (EPC valve) troller controls output to the dump control valve
5. Body positioner sensor (EPC valve).
q The signal from the dump lever is controlled by
6. Hoist cylinder the retarder controller, and actuates the dump
7. Manual body lowering valve control valve (EPC valve). The pilot pressure
Serial No.: q and up generated by the dump control valve (EPC
valve) moves the spool of the hoist valve and
controls the hoist cylinder.
q If the body does not lower because of a trouble
in the controller or electrical equipment, open
manual body lowering valve (7) and drain the
body holding oil in hoist cylinder (6) to the tank
to lower the body.
(For the operating procedure, see Testing and
adjusting.)
4 HD465-7E0, HD605-7E0
Hydraulic tank 1
1. Breather
2. Drain
3. Oil level gauge
Capacity: 97 l
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Steering cylinder 1
Unit: mm
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
HD465-7E0, HD605-7E0 11
Steering control valve 1
12 HD465-7E0, HD605-7E0
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}
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 17
Hoist valve 1
18 HD465-7E0, HD605-7E0
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}
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 23
Dump control valve (EPC valve) 1

HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10612
HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10612
1. Manual operation button Function

2. Solenoid assembly (Solenoid a) q The EPC valve controlled by the retarder con-
3. Relief valve (R) troller switches the pilot pressure of the hoist
4. Solenoid assembly (Solenoid b) valve, and controls pressure, and controls the
hoist valve.
A: To hoist valve (RAISE side)
B: To hoist valve (LOWER side)
P2: Pick up port
T1: To hydraulic tank
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
HD465-7E0 Serial No.: 10614 and up

26 HD465-7E0, HD605-7E0
1. Manual operation button

2. Solenoid assembly (Solenoid a)
3. Relief valve (R)
4. Solenoid assembly (Solenoid b)
5. Strainer
A: To hoist valve (RAISE side)

B: To hoist valve (LOWER side)
P1: From hydraulic tank
P2: Pick up port
Function
q The EPC valve sends the oil from the hydraulic
pump to the hoist valve spool to change the
pilot pressure and control the hoist valve.
HD465-7E0, HD605-7E0 27
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
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
28 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 29
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}
30 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 31
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}
32 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 33

© 2009 KOMATSU
All Rights Reserved
34 HD465-7E0, HD605-7E0
SEN04679-00
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Work equipment (Body)
Auto greasing system ..................................................................................................................................... 2
HD465-7E0, HD605-7E0 1
Auto greasing system 1
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3
1. Flow divider valve (1) q Automatic greasing point

2. Flow divider valve (2)
Flow divider
3. Flow divider valve (3) No. Greasing point
valve No.
5. Flow divider valve (5) 1 Front suspension upper pin (left) (1)
6. Flow divider valve (6) 2 Tie rod center lever pin (right) (2)
7. Flow divider valve (7) 3 Tie rod end pin (left)
4 Steering cylinder end pin (left) (1)
10. Branch block 5 King pin (left)
11. Electric grease pump 6 Center lever pin
12. Controller (4)
7 Steering cylinder frame pin (right)
8 Steering cylinder frame pin (left)
9 Tie rod center lever pin (left)
(2)
10 A-frame front pin (left)
11 A-frame rear pin (left)
12 A-frame front pin (right)
(4)
13 A-frame rear pin (right)
14 Tie rod end pin (right)
15 King pin (right)
(3)
16 Steering cylinder end pin (right)
17 Front suspension upper pin (right)
18 Hoist cylinder upper pin (right) (5)
19 Hoist cylinder lower pin (right) (6)
20 Lower rod frame pin (right) (5)
21 Lower rod frame pin (left) (7)
22 Hoist cylinder lower pin (left) (6)
23 Hoist cylinder upper pin (left) (7)
24 Body hinge pin (right) (5)
25 Rear suspension lower pin (right) (8)
26 Rear suspension upper pin (right) (5)
27 Upper rod axle pin (right) (8)
28 Upper rod frame pin (right) (5)
29 Lower rod axle pin (right) (8)
30 Lower rod axle pin (left) (9)
31 Upper rod frame pin (left) (7)
32 Upper rod axle pin (left) (9)
33 Rear suspension upper pin (left) (7)
34 Rear suspension lower pin (left) (9)
35 Body hinge pin (left) (7)
4 HD465-7E0, HD605-7E0
System diagram
HD465-7E0, HD605-7E0 5
Operation
q The automatic greasing system adds the hours of operation of the equipment, and every time the total
reaches 2 hours, it carries out greasing.
q Operation is sensed by checking the controller power ON signal output when the starting switch is
turned ON.
q The amount of grease for each work equipment pin is set according to the load on the pin.
Item Unit Specification value
Greasing interval Hour (H) 2
Greasing time Minutes (min) 15
When starting switch is turned on and controller power source is
Automatic Method of Start of calculation turned on
greasing calculating
controller When starting switch is turned off and controller power source is
greasing End of calculation
turned off
interval (See
figure below) Greasing timing When total calculation for greasing interval (hatched area) Reaches 2
hours
Max. pressure kg/cm2 245
Discharge amount cc/min 12
Electric
grease pump Tank capacity cc 1,600
G2-L1 (For standard specification, when machine is shipped)
Grease used –
*G0-L1(For cold areas, available for supply)
6 HD465-7E0, HD605-7E0
Flow divider Amount of

No. Greasing point
valve No. grease
1 Front suspension upper pin (left) (1) 0.15
2 Tie rod center lever pin (right) (2) 0.65
3 Tie rod end pin (left) 0.65
4 Steering cylinder end pin (left) (1) 0.65
5 King pin (left) 0.65
6 Center lever pin 0.65
(4)
7 Steering cylinder frame pin (right) 0.65
8 Steering cylinder frame pin (left) 0.65
9 Tie rod center lever pin (left) 0.65
(2)
10 A-frame front pin (left) 0.65
11 A-frame rear pin (left) 0.65
12 A-frame front pin (right) 0.65
(4)
13 A-frame rear pin (right) 0.65
14 Tie rod end pin (right) 0.65
15 King pin (right) 0.65
(3)
16 Steering cylinder end pin (right) 0.65
Flow divider Amount of cc each 17 Front suspension upper pin (right) 0.15
valve grease time
18 Hoist cylinder upper pin (right) (5) 0.25
19 Hoist cylinder lower pin (right) (6) 0.25
20 Lower rod frame pin (right) (5) 0.65
21 Lower rod frame pin (left) (7) 0.65
22 Hoist cylinder lower pin (left) (6) 0.25
23 Hoist cylinder upper pin (left) (7) 0.25
24 Body hinge pin (right) (5) 0.55
25 Rear suspension lower pin (right) (8) 0.65
26 Rear suspension upper pin (right) (5) 0.25
27 Upper rod axle pin (right) (8) 0.65
28 Upper rod frame pin (right) (5) 0.65
29 Lower rod axle pin (right) (8) 0.65
30 Lower rod axle pin (left) (9) 0.65
31 Upper rod frame pin (left) (7) 0.65
32 Upper rod axle pin (left) (9) 0.65
33 Rear suspension upper pin (left) (7) 0.25
34 Rear suspension lower pin (left) (9) 0.65
35 Body hinge pin (left) (7) 0.55
HD465-7E0, HD605-7E0 7
Components of system
Controller
1. Connector (CN1) CN1

2. Connector (CN2)
No. Name of signal Input/output signal
3. Controller
4. Fuse 1 – –
2 – –
Specification 3 – –
Model: LC2MP
4 Battery 24V Input
5 Earth Output
6 ACC Input
CN2
No. Name of signal Input/output signal
1 Motor Input
2 Pressure pickup switch Input
3 Motor Output
4 Pressure pickup switch Output
8 HD465-7E0, HD605-7E0
Electric grease pump
1. Motor Specification
2. Tank Model: LD10FP
3. Air bleed plug
4. Pump
5. Pressure switch
6. Connector
HD465-7E0, HD605-7E0 9
Operation q When the pressure inside the pump rises and

goes above the set pressure, indicator (10) is
1) Greasing, pressurizing pushed to the left, pressure switch (11) is
q When motor (1) rotates in the normal direction, switched ON, and motor (1) stops.
eccentric shaft (2) rotates counterclockwise q When the pressure goes down again and pres-
and pump piston (4) is operated in a reciprocal sure switch (11) is turned OFF, motor (1) starts
movement by link plate (3). again and the pressurized condition is main-
q During the return stroke (i) of pump pump tained.
piston (4), the grease inside tank (5) is sucked
in, and on the discharge stroke (o), check
valve (6) is pushed open and the grease is
pushed out to discharge port (P).
q Pressure release spool (7) is moves to the
right by pin (8) of eccentric shaft (2) and pres-
sure release hook (9). This shuts off discharge
port (P) and return passage (T), so the pres-
surized condition is maintained.
10 HD465-7E0, HD605-7E0
q If abnormal pressure is generated in the circuit 2) Release of pressure, waiting for work
at discharge port (P) end, safety valve (12) q When the greasing is completed, motor (1)
opens and releases the pressure to return cir- rotates in reverse, and eccentric shaft (2)
cuit (T) to protect the equipment from damage. rotates clockwise.
q Pressure release spool (7) is moved to the left
by pin (8) of eccentric shaft (2) and pressure
release hook (9).
q As a result, discharge port (P) and return cir-
cuit (T) are interconnected, and the pressure in
the circuit is released to tank (5).
q When this happens, pump piston (4) moves in
a reciprocal motion, but the discharged grease
flows to return circuit (T), so the pressure does
not rise.
q When the pressure in the circuit drops, indica-
tor (10) is pushed back, and pressure switch
(11) is turned OFF motor (1) stops.
If pressure switch (11) is not turned off, the
controller automatically rotates motor (1) in the
opposite direction to release the pressure.
HD465-7E0, HD605-7E0 11
Flow divider valve
(1) Left front side
A: From electric grease pump

B: Front suspension upper pin (left)
C: Tie rod end pin (left)
D: Steering cylinder end pin (left)
E: King pin (left)
12 HD465-7E0, HD605-7E0
(2) Left front side

B: A-frame front pin (left)
C: A-frame rear pin (left)
D: Steering cylinder frame pin (left)
E: Tie rod center lever pin (left)
F: Tie rod center lever pin (right)
HD465-7E0, HD605-7E0 13
(3) Right front side

B: King pin (right)
C: Steering cylinder end pin (right)
D: Tie rod end pin (right)
E: Front suspension upper pin (right)
14 HD465-7E0, HD605-7E0
(4) Right front side

B: Center lever pin
C: A-frame front pin (right)
D: A-frame rear pin (right)
E: Steering cylinder frame pin (right)
HD465-7E0, HD605-7E0 15
(5) Right rear side

B: Lower rod frame pin (right)
C: Upper rod frame pin (right)
D: Body hinge pin (right)
E: Hoist cylinder upper pin (right)
F: Rear suspension upper pin (right)
16 HD465-7E0, HD605-7E0
(6) Center rear side

B: Hosit cylinder lower pin (right)
C: Hosit cylinder lower pin (left)
D: To flow divider valve (9)
HD465-7E0, HD605-7E0 17
(7) Left rear side

B: Rear suspension upper pin (left)
C: Hoist cylinder upper pin (left)
D: Body hinge pin (left)
E: Upper rod frame pin (left)
F: Lower rod frame pin (left)
18 HD465-7E0, HD605-7E0
(8) Right rear side
A: To flow divider valve (5)

B: Rear suspension lower pin (right)
C: Lower rod axle pin (right)
D: Upper rod axle pin (right)
E: From electric grease pump
HD465-7E0, HD605-7E0 19
(9) Right rear side

B: Upper rod axle pin (left)
C: Lower rod axle pin (left)
D: Rear suspension lower pin (left)
20 HD465-7E0, HD605-7E0
Structure
1. Measurement piston A: Discharge port

2. Head B: Discharge port
3. Body C: Measurement chamber
4. Spring D: Piston chamber
5. Spring retainer E: Oil passage
6. Pilot piston F: Supply port
HD465-7E0, HD605-7E0 21
Operation q Measurement piston (1) is pushed down by the

grease in piston chamber (D), and the grease
1) Supply in measurement chamber (C) is discharged to
q When grease from the pump is supplied to the work equipment pins from discharge ports
supply port (F), the pressure at supply port (F) (A) and (B).
rises and pilot piston (6) is pushed up. q At the end of this stroke, pilot piston (6) is
q As a result, oil passage (E) opens and the pushed back down by measurement piston (1),
grease enters piston chamber (D) of measure- and supply port (F) and oil passage (E) are
ment piston (1) from oil passage (E) closed.
q In this way, the measurement and discharge
process for one cycle is completed.
22 HD465-7E0, HD605-7E0
2) Resetting
q When the pump enters the pressure release
mode, measurement piston (1) is pushed back
up by spring (4).
q When this happens, the grease in piston
chamber (D) passes from oil passage (E)
through the inside of pilot piston (6), and enters
measurement chamber (C) to reset the system
to the initial stage in preparation for the next
time of actuation.
HD465-7E0, HD605-7E0 23

© 2008 KOMATSU
All Rights Reserved
24 HD465-7E0, HD605-7E0
SEN01095-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 3
Rear view monitor ........................................................................................................................................... 9
HD465-7E0, HD605-7E0 1
ROPS cab 1
1. Front wiper
2. Front glass
3. Air conditioner fresh filer
4. Door (Left)
5. Rear glass
6. Door (Right)
7. Washer tank
2 HD465-7E0, HD605-7E0
Air conditioner 1
1. Receiver dryer
2. Air conditioner unit
3. Compressor
4. Condenser
5. Hot water return port
6. Hot water take-off port
Function
q The air conditioner makes a pleasant operating
environment in the cab for the operator and
acts to reduce fatigue.
HD465-7E0, HD605-7E0 3
Refrigerant flow system
4 HD465-7E0, HD605-7E0
Air conditioner unit
1. Hot water outlet port Outline

2. Hot water inlet port q The vertical air conditioner unit on which evap-
3. Refrigerant gas inlet side orator and heater core is synchronized with the
4. Refrigerant gas outlet side blower and intake unit to generate cool and hot
air.
q The temperature adjusting switch on the air
conditioner panel controls air mix dampers to
adjust the spurting out temperature.
Cooler
q The cooler circulates refrigerant through evap-
orator to cause heat exchange (dehumidifica-
tion and cooling).
q Air taken in by the blower and intake unit is
cooled with evaporator and then blown out
from the grill through the duct.
Heater
q The heater circulates engine coolant in heater
core to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core and then blown out
from the grill through the duct.
HD465-7E0, HD605-7E0 5
Receiver dryer
1. Sight glass Function

q It is used to store liquefied high-pressure, high-
A: From condenser temperature refrigerant from the condenser. It
B: To air conditioner unit is capable of completely liquefying the refriger-
ant even when bubbles are contained in refrig-
erant due to the condenser condition in heat
dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Mass of desiccating agent (g) 300
6 HD465-7E0, HD605-7E0
Condenser
1. Fin Function
2. Tube q It cools and liquefies the high-pressure and
high-temperature gas which compressed by
A: Refrigerant gas inlet port compressor.
B: Refrigerant gas outlet port a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m2) 6.55
Max. pressure used (MPa {kg/cm2}) 3.6 {3.6}
HD465-7E0, HD605-7E0 7
Compressor
1. Case Function
2. Clutch q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
A: Suction service valve tor to high-pressure, high-temperature gas so
B: Discharge service valve that it may be easily regenerated (liquefied) at
normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinder – Bore x Stroke
7 – 29.3 x 27.4
(mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed (rpm) 4,000
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume (cc) 135
8 HD465-7E0, HD605-7E0
Rear view monitor 1

(If equipped)
1. Monitor
2. Camera
3. Cable
HD465-7E0, HD605-7E0 9
Monitor
1. Auto switch Specifications

2. Manual switch TV signal method:
3. Zoom/Iris switch As per Japanese standard TV method
(Reverse light compensation switch) Scanning method: 2:1 Interlace method
4. Bright/Dim light selector switch CRT: 4.5 inch, black and white, 90-deg. deflection
5. Mark switch Resolution:
Horizontal 400 lines and vertical 300 lines
6. Contrast adjustment knob
Power supply voltage: DC 24/12 V
7. Brightness adjustment knob
10 HD465-7E0, HD605-7E0
Camera
1. Camera Specifications
2. Connector TV signal method:
As per Japanese standard TV method
Scanning method: 2:1 Interlace method
Image sensor:
1/4 inch color CCD with 250,000 pixels
Lens: 1.7 mm, 1:2.8
Angle of view: Horizontal; Approx. 118 deg.,
Vertical; Approx. 97.6 deg.
Electronic zoom: Approx. 1.4 power
Using luminance range:
Min. luminance of object; 3 lux
Power supply voltage:
DC 5.5 V – 99.5 V for main unit
(supplied by monitor)
Power consumption: Max. 120 mA
HD465-7E0, HD605-7E0 11

© 2007 KOMATSU
All Rights Reserved
12 HD465-7E0, HD605-7E0
SEN01096-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
46. Rotary switch [SW1] a Do not change setting.

47. Rotary switch [SW2] a When moving the switches, use a precision
48. Rotary switch [SW3] screwdriver and turn slowly.
49. Dipswitch [SW5-4] a Be careful not to touch anything except the
50. Dipswitch [SW5-3] switches inside the grommet.
51. Dipswitch [SW5-2] a Be careful not to let any dirt or dust get in.
52. SI Spec, Non-SI Spec selection switch [SW5-1] a After completing the setting, return the grom-
53. Dipswitch [SW6-4] met securely to its original position.
54. Dipswitch [SW6-3]
HD465-7E0, HD605-7E0 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-
No. Display
item
Display
category Device Color Display range/
conditions
Display
method
Central monitor ately Remarks
warn- Alarm check after
ing buzzer switch is turning
lamp oper- key ON.
ated.
Note: When machine

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

Backlight LED Amber small lamp is operation — —
lit up.
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 ment ground 0 – 3,400 rpm is operated, —
(Note) position and
Engine color: the buzzer and moves around
2 central warn-
speed black indication range
ing lamp are and then returns
turned ON. to starting point.

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

monitor check
Scale: switch is oper-
white, red 50 – 150°C ated, pointer
Gauge Move- Back- (120°C or Analog — — — starts at current
ment ground higher in the red display (Note) position and
Oil tem- color: zone) 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
Backlight LED Amber small lamp is operation. — —
lit up.
Note: When machine

Scale: monitor check
switch is oper-
Back-
Move- ground (120°C or Analog starts at current
Gauge — — —
ment color: higher in the red display (Note) position and
Oil tem- zone) 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
lit up.
6 HD465-7E0, HD605-7E0
Related When
operation machine Immedi-
monitor
No. Display
item
Display
conditions
Display
method check ately
after Remarks
Central switch is turning
warn- Alarm oper-
ing buzzer ated. key ON.
lamp
Note: When machine
monitor check
Gauge Move- Back- (102°C or Analog — — — starts at current
ment ground higher in the red display (Note) position and
Coolant color: zone) moves around
5 temper- black indication range
11 ature and then returns
to starting point.
Caution LED Red At 102°C or Lit up during

higher warning
lit up.
Note: When machine
monitor check
white, red ated, pointer
Move- Back- Analog starts at current
Gauge EMPTY – FULL — — —
ment ground display (Note) position and
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)
When the small Lit up during
Backlight LED Amber 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 upper column.
Note 2 Note 2:"Program
code code black played in the No." is
7 LCD 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 For information on how
displayed in to operate display, see
Failure Failure problem or the upper col-
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.
HD465-7E0, HD605-7E0 7
Related When
monitor ately
No. Display
item
Display
conditions
Display
method check after Remarks
Central Warn- switch is turning
warning oper- key ON.
ing ated.
lamp buzzer
Reverse
travel
integrating
meter Display Switch screen
Reset of character: Press machine by operating
time to black monitor mode machine For details, see the
Other selector switch
displays change fil- LCD Back- monitor mode Operation & Mainte-
ter and oil. ground " " selector nance Manual.
Telephone color: switch
7 number green ">" or "<".
setting
Language
selection
Dimmed
Night When the down by a
Backlight LED Green small lamp is step when the — —
lighting lit up. small lamp is
lit up.
Central During system Lit up when
8 warning LED Red
is abnormal abnormal.
lamp
Note 1:The moment
when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
Mainte- nance-related has been given
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
operation.
ated and the shift lever
caution operated. (Note) (Note) 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
optional
LED Red machine moni-
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 HD465-7E0, HD605-7E0
Related When
monitor ately
No. Display
item
Display
conditions
Display
ing ated.
lamp buzzer
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 During non- other than the "N"
caution manual (Note) (Note)
operation: position.
turned OFF.
During
Emer- operation:
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 — —
high During non-
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
HD465-7E0, HD605-7E0 9
Related opera- When

tion machine Immedi-
monitor ately
No. Display
item
Display
conditions
Display
ing ated.
lamp buzzer
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
(power
LED Green mode
lit up — —
During non-
mode)
operation:
turned OFF
Economy
Output mode
mode in operation:
At economy
35 (econ- LED Green mode
lit up — —
omy During non-
mode) operation:
turned OFF
Suspen-
sion mode At suspension Lit up in
36
(hard) (if
LED Green "hard" mode "hard" mode
— —
equipped)
10 HD465-7E0, HD605-7E0
Related opera- When

tion machine Immedi-
monitor ately
No. Display
item
Display
conditions
Display
ing ated.
lamp buzzer
Suspen-
sion
Lit up in
mode In suspension
37 LED Green "medium" — —
(medium) "medium" mode
mode
(if
equipped)
Suspen-
sion
In suspension Lit up in "soft"
38 mode LED Green — —
"soft" mode mode
(soft) (if
equipped)
During
operation:
When ABS is
ABS (if lit up
39 LED Orange operated. — —
equipped) During non-
operation:
turned OFF
During
operation:
When ASR is
ASR (if lit up
40 LED Orange operated.
equipped) During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lit up
41
ing
LED Red for preheating
During non-
— —
engine is
Pilot operation:
operated.
turned OFF
Auto-
matic When auto- When ready
retarder matic retarder is to be
42
being
LED Green 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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 13
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.
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 15
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.
16 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 17
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)
(HD465/605-7E0)
7 Exhaust temperature (REAR) 42611 EXHAUST TMP R Display exhaust temperature (REAR)
(HD465/605-7E0)
8 Exhaust temperature (REAR) 42613 EXHAUST TMP R Display exhaust temperature (REAR)
(HD465/605-7E0)
9 Inclinometer (pitch angle) 32901 INCLINOMETER Display inclination angle
10 Inclinometer (pitch angle) 32902 INCLINOMETER Display voltage
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.)
18 HD465-7E0, HD605-7E0
–30 to +100 [?],

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 [?]

0 to 5 [V]
2.2 [V] at 300 [?]
3.9 [V] at 700 [?]

200 – 950 [?]

0 to 5 [V]
2.2 [V] at 300 [?]
3.9 [V] at 700 [?]
Flat ground: 0.0 [° ] (When Front up: plus, Mea- When PLM (having VHMS) is setted up.
surement 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]
HD465-7E0, HD605-7E0 19
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
20 HD465-7E0, HD605-7E0

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
(HD465/605-7E0)
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
HD465-7E0, HD605-7E0 21
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.
22 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 23
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.
24 HD465-7E0, HD605-7E0
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
Q Q Q Q improper connector connection
(OPEN)
– – – – – (–) : NON CONNECT
HD465-7E0, HD605-7E0 25
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.
26 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 27
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
28 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 29
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
30 HD465-7E0, HD605-7E0
Model name
Signal name HD325-7 HD465-7E0 HD465-7R Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD465-7E0, HD605-7E0 31
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
32 HD465-7E0, HD605-7E0
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
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD465-7E0, HD605-7E0 33
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
34 HD465-7E0, HD605-7E0
SEN01097-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Automatic shift control system ........................................................................................................................ 2
Transmission controller ................................................................................................................................... 6
Automatic emergency steering system ......................................................................................................... 20
Automatic suspension system ...................................................................................................................... 24
Retarder control system................................................................................................................................ 27
Battery disconnector switch .......................................................................................................................... 38
Dump control lever........................................................................................................................................ 44
HD465-7E0, HD605-7E0 1
Automatic shift control system 1

1. Electrical circuit diagram
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3
Outline RTCDB2(Machine monitor, retarder controller, and

q Upon receiving the shift position signal of the other) (Updated every 100 msec)
gear shift lever, accelerator position signal of No. Item
the accelerator pedal, the speed signal of the
1 Gear speed
transmission, and signals of various switches
2 Shift lever position
and sensors, the transmission controller auto-
3 Lock-up operation state
matically sets the transmission in the most suit-
able gear speed. 4 Torque converter state
q The transmission controller controls the torque 5 Emergency escape state
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 state
Each of the clutch packs of the transmission 8 Option setting abnormality state
and the torque converter lockup clutch pack 9 Neutral safety alarm command
has the electronically controlled modulation 10 Overrun alarm command
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 coolant temperature
sion controller sends them to the network. 20 Engine speed
21 Momentary fuel consumption
Data items transmitted from transmission con- 22 Body seating state
troller to network 23 Float caution command
24 Auto suspension mode
RTCDB1(Machine monitor, retarder controller, and
25 Retarder brake signal
other) (Updated every 10 msec)
26 Parking brake signal
No. Item 27 –
1 Output shaft speed Tail lamp operation (secondary brake operation
28
2 – recognition)
3 Brake command value (Rear wheel) 29 ARSC operation (ready lamp)
4 – 30 ASR command (oparation ON/OFF)
31 ABS operation state
Retarder controller model setting abnormality
RTCDB1(Dedicated to engine controller) 32
state
(Updated every 10 msec)
Retarder controller option setting abnormality
33
No. Item state
1 Throttle correction value 34 Accumulator oil pressure drop state (front,rear)
2 Throttle lower limit 35 ARSC overheat alarm
3 Throttle upper limit 36 ABS controller model setting abnormality state
4 2nd method throttle 37 ABS controller option setting abnormality state
5 HS line / brake point speed 38 ARSC setting travel speed
6 Torque curve select (engine mode) 39 –
7 ABS reference type 40 Retarder oil temperature (rear)
8 Droop switch 41 Body positioner signal
9 ABS droop trim
RTCDB2(Dedicated to engine controller)
(Updated every 100 msec)
No. Item
1 Automatic warn-up cansel flag
4 HD465-7E0, HD605-7E0
Data item transmitted from the transmission RPC-k (irregularly updated)

controller to the network
No. Item
1 Model selection information
RTCDB1 (Updated every 10 msec)
Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator position 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) state f. Tipping alarm function Installed/Not installed
7 Foot brake (service brake) state g. ABS function Installed/Not installed
h. Parking brake interlock provided / not pro-
vided
RTCDB2 (Updated every 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 state
8 Engine coolant temperature
9 Control state of grid heater
10 Momentary fuel consumption
11 Parking brake state
12 Retarder brake state
13 Body seating
14 Hoist lever state
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
state
Retarder controller model setting abnormality
26
state
27 Body position sensor
28 ABS operation state
ABS controller option setting abnormality
29
state
ABS controller model setting abnormality
30
state
HD465-7E0, HD605-7E0 5
Transmission controller 1
Outline
q The transmission controller controls the trans- 8. The self-diagnostic function is installed for
mission system. each of the input and output systems.
It has the following features and functions. 9. The self-diagnostic function is displayed
1. The gear shifting patter is set in the power on the monitor.
mode or economy mode. 10. If a trouble is detected, its contents are
2. In the braking mode, the brake is used and sent to the network.
the gear shifting point is heightened to in- 11. It uses the machine monitor to display if the
crease the brake cooling pump speed. Ac- failure is still existing.
cordingly, the retarder cooling effect is 12. It provides an escape function for use
increased and the engine is used as a when there is a failure in the electrical sys-
brake efficiently. tem.
3. It controls the brake through the retarder
controller for the torque converter lock-up
solenoid valve and overrun prevention.
4. To reduce the gear shift shocks, the throt-
tle correction command is output to the en-
gine controller to adjust the engine speed
during gear shifting operation.
5. Speed sensors are installed to 3 places of
the transmission input shaft, intermediate
shaft and output shaft to sense slip of the
transmission clutch and protect the trans-
mission when the hydraulic system has a
trouble.
6. It connects to the network and shares var-
ious data with other controllers.
7. It receives the model selection data (what
model it is mounted on) through the net-
work.
6 HD465-7E0, HD605-7E0
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 speed, output shaft Input
speed)
10 – – 30 Transmission output shaft speed 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 speed) Input
20 Transmission intermediate shaft speed Input 40 Transmission input shaft speed 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
HD465-7E0, HD605-7E0 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.
Gear shifting 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 difference between the shift-down point and the
Mode Set conditions shift-up point is increased to reduce the number of
Braking mode Brake signal ON
unnecessary gear shifting operations.
When either of the following conditions are Partial delay:

Coasting fulfilled
mode 1. Brake signal OFF Unnecessary gear shift operations caused by the
2. Accelerator idle change of the mode are reduced.
When following conditions are satisfied
1. Within certain time after brake signal is turned Power mode:
Partial delay OFF The power mode uses the power of the machine to
2. Accelerator pedal is not in idle position or full
position
the maximum to provide the maximum payload.
However, when the machine is unloaded or has only
When the following conditions are fulfilled a light load (high acceleration), an acceleration sen-
1. Certain time after brake signal is turned OFF
Power mode
2. Accelerator pedal depressed sitive type variable shifting point is used. This de-
3. Power mode selector switch is at power tects the acceleration of the machine and shifts the
When the following conditions are fulfilled
transmission up sooner to provide better accelera-
Economy 1. Certain time after brake signal is turned OFF tion and to reduce the fuel consumption, noise, and
mode 2. Accelerator pedal depressed transmission shock.
3. Power mode selector switch is at economy
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower
level, and the fuel consumption, noise, and trans-
mission shock are reduced. In this mode, the maxi-
mum engine output is limited.
8 HD465-7E0, HD605-7E0
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 down a slope with the foot brake applied and
q The optimum shift-up point is selected the engine speed is kept low by the gear speed
between 2,100 and 1,750 rpm according to the maintaining function, the cooling oil becomes
accelerating condition of the machine and gear insufficient and the brake tends to overheat.
speed. q If the travel speed lowers below 1 km/h or the
q The optimum shift-down point is selected foot brake is not applied or the lock-up is kept
between 1,200 and 1,400 rpm according to the turned on for a long period, the lock-up is
accelerator pedal position and gear speed. turned off and a gear speed proper for the
travel speed is selected.
2. Economy mode
q The optimum shift-up point is selected 4. Lock-up
between 2,100 and 1,750 rpm according to the q The point to turn ON the torque converter lock-
accelerating condition of the machine and gear up is set properly in the range from 1,250 to
speed. 1,500 rpm according to the torque converter
q The optimum shift-down point is selected inlet speed (engine speed) and outlet speed
between 1,200 and 1,400 rpm according to the (transmission input shaft speed) and accelera-
accelerator pedal position and gear speed. tor pedal position.
q The lockup-off point is 1,100 rpm.
3. Braking mode
q When the machine moves off downhill with the
q While the foot brake is operated, if the travel
accelerator pedal released, the lock-up is not
speed lowers below about 20 km/h at the 4th
en ga ged u nt il l th e ac c el er a tor pe dal is
gear speed, about 15 km/h at 3rd gear speed,
depressed or foot brake is applied.
or 11 km/h at the 2nd gear speed, the current
gear speed (F4, F3, or F2) is maintained.
Accordingly, if the operator drives the machine
HD465-7E0, HD605-7E0 9
Gear shift lever positions and method of shift- 4) Gear shift lever position N
ing At the neutral position, none of the transmis-
1) Gear shift lever position D sion clutches are actuated.
When shifting up (in power mode)
I) When the gear shift lever is set at position D, Time when gear cannot be shifted
the transmission is set to F2 torque converter q In the automatic shift range, no-shift time is
range. secured during each gear shifting operation to
II) When the accelerator pedal is depressed, the prevent a malfunction caused by transient
engine speed rises and accelerates. When the change of the speed at the gear shifting opera-
transmission input shaft speed reaches 1,250 tion. The gear is not shifted in this no-shift
– 1,500 rpm, the lock-up clutch is engaged, so time.
the torque converter is directly engaged and q The no-shift time is controlled finely for each
the transmission is set to direct travel. gear shift pattern by the all-range electronic
III) As the engine speed rises further and reaches modulation system.
1,750 – 2,100 rpm, the transmission shifts up
to F3. The no-shift time for each gear shift pattern is
While the transmission is shifting up, the roughly shown below.
engine speed is also lowered (a command is
output to the engine controller) in order to
reduce the shock when shifting gear.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine
accelerates, it rises again and the transmission
shifts up 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 down, the
engine speed is also raised (a command is
output to the engine controller) in order to
reduce the shock when shifting gear.
II) As the engine speed goes down further and
the transmission shifts down to F2, the torque
converter lock-up clutch is disengaged and the
transmission enters the torque converter drive.
a The set speed and operating condition in the

above explanation are subject to change,
depending on the travel condition. For details,
see the automatic gear shifting 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
These gear shift lever positions are for reverse
travel.
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 HD465-7E0, HD605-7E0
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 according to the actuated.
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 gearshift 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 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)
HD465-7E0, HD605-7E0 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 No. is output (Soft logic part
version No.)
3 Data version 20224 VERSION (DATA) Software version No. is output (Soft data part
version No.)
4 Transmission input shaft speed 31200 T/M SPEED:IN Input shaft speed is output
5 Transmission intermediate shaft 31300 T/M SPEED:MID Intermediate shaft speed is output
speed
6 Transmission output shaft speed 31400 T/M SPEED:OUT Output shaft 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) is out-
put
11 Torque converter oil temperature 30101 T/C OIL TEMP Torque converter oil temperature (A_IN_1) voltage
is output
12 Transmission oil temperature 32500 T/M OIL TEMP Transmission oil temperature is output
13 Transmission oil temperature 32501 T/M OIL TEMP Transmission oil temperature voltage is output
14 Steering oil temperature 32701 STRG OIL TEMP Steering oil temperature (A_IN_3) 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 pressure 32600 T/C OIL PRESS Torque converter oil pressure (A_IN_10) conver-
sion value is output
17 Torque converter oil pressure 32605 T/C OIL PRESS Torque converter oil pressure (A_IN_10) of input
voltage 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 ECMV output command current to HIGH clutch is
output
23 Solenoid output (L) 31601 ECMV L DIR ECMV output command current to LOW clutch is
output
24 Solenoid output (1st) 31602 ECMV 1 DIR ECMV output command current to 1st clutch is
output
25 Solenoid output (2nd) 31603 ECMV 2 DIR ECMV output command current to 2nd clutch is
output
12 HD465-7E0, HD605-7E0
Data range Remarks

Depending upon software part number
Depending upon software version No.
x1 [min-1] (0 – 32767 [min-1])

---- [Other than 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])
HD465-7E0, HD605-7E0 13

ECMV output command current to 3rd clutch is
26 Solenoid output (3rd) 31604 ECMV 3 DIR
output
27 Solenoid output (4th) 31605 ECMV 4 DIR ECMV output command current to 4th clutch is
output
ECMV output command current to REV clutch is
28 Solenoid output (R) 31606 ECMV R DIR
output
ECMV output command current to lockup clutch is
29 Solenoid output (Lockup) 31609 ECMV LU DIR
output
30 Angle sensor 32900 ANGLE SENSOR Angle sensor input (A_IN_7) angle conversion 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 to be sent to engine con-
34 Throttle modified value 36000 THROTTLE MOD
troller is output
35 Low clutch trigger modification value 38900 TRIGGER MOD L Low clutch trigger modification value is output (all
oil temperature mode)
36 High clutch trigger modification value 38901 TRIGGER MOD H High clutch trigger modification value is output (all
oil temperature mode)
37 1st clutch trigger correction value 38902 TRIGGER MOD 1 1st clutch trigger correction value is output (all oil
temperature mode)
14 HD465-7E0, HD605-7E0
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 [%])
Hexadecimal number show below
Display of 8 characters
AABBCCDD
AA: Low temperature correction value [x10msec]
BB: Medium temperature correction value [x10msec]
CC: Normal temperature correction value [x10msec]
DD: High temperature correction value [x10msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]

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

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

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HD465-7E0, HD605-7E0 15

38 2nd clutch trigger correction value 38903 TRIGGER MOD 2 2nd clutch trigger correction value is output (all oil
temperature mode)
39 3rd clutch trigger correction value 38904 TRIGGER MOD 3 3rd clutch trigger correction value is output
(all oil temperature mode)
40 4th clutch trigger correction value 38905 TRIGGER MOD 4 4th clutch trigger correction value is output
(all oil temperature mode)
41 Reverse clutch trigger correction 38906 TRIGGER MOD R Revolution clutch trigger correction value is output
value (all oil temperature 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 HD465-7E0, HD605-7E0
Data range Remarks

AABBCCDD

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

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

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

(Each range: -1.28 (80) – +1.27 (7F) [sec])
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
HD465-7E0, HD605-7E0 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 is output
(Last gear shifting condition)
x10 [msec] (0 – 2.55 [sec], No fill :0)
45 Fill time (H) 41801 FILL TIME H High clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
46 Fill time (1) 41802 FILL TIME 1 1st clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
47 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
48 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
49 Fill time (4) 41805 FILL TIME 4 4th clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (R) 41806 FILL TIME R REV clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Throttle lower limit output 44201 THROT LIMIT LO Throttle lower limit to be sent to engine controller
is output
x0.1 [%] (0 – +100.0 [%])
52 Throttle higher limit output 44200 THROT LIMIT HI Throttle higher limit to be sent to engine controller
is output
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 state of SOL_OUT_0 - 7. When
power supply output is set, 0 is displayed.
59 Output signal D_OUT_8-15 40950 D-OUT-8-----15 Corresponds to SOL_OUT_8, 9, 10A, 10B, 11A,
11B, SIG_OUT_0 and SIG_OUT1. When power
supply output is set, 0 is displayed.
60 Output signal D_OUT_16-23 40951 D-OUT-16----23 Corresponds to SIG_OUT_2, 3, HSW_OUT_0, 1,
BATT_RY_OUT. When power supply output is set,
0 is displayed.
18 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 21
Emergency steering motor
1. Terminal E Function
2. Terminal M q If there is an abnormal drop in the oil pressure
in the steering circuit, the emergency steering
motor receives a signal from the transmission
controller and drives the emergency pump.
Specifications
Type DC motor
Rated voltage 24V
Rated output 0.9kW
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
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
24 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 25
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.
26 HD465-7E0, HD605-7E0
Retarder control system 1
HD465-7E0, HD605-7E0 27
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
28 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 29
Retarder controller list of real-time monitoring display contens

The input and output signal states of the retarder controller can be checked with the real-time monitoring
function of the machine monitor.
Real-time monitoring display items related to retarder controller and contents displayed in normal state are
as follows.
1 Part No. of software 20214 VERSION Mass production software part number is output
2 Application version 20231 VERSION(APP) Software version No. is output (soft logic part ver-
sion No.)
3 Data version 20232 VERSION(DATA) Software version No. is output (soft data part ver-
sion No.)
4 ARSC set switch 37701 ARSC SET SP SW A_IN_8
5 Transmission output shaft speed 31403 T/M SPEED:OUT PLS_IN1

Transmission output shaft speed is output
6 Wheel speed (left) 39705 WHEEL SPEED L PLS_IN2
Wheel speed is output.
7 Wheel speed (right) 39704 WHEEL SPEED R PLS_IN3
Wheel speed is output.
8 Retarder cooling oil temperature 30211 BRAKE OIL T R Converted temperature of retarder oil temperature
(rear) sensor (rear) (A_IN_2) is output.
9 Retarder cooling oil temperature 30212 BRAKE OIL T R A_IN_2
(rear)
10 Brake output (front wheel) 33700 BK OUTP DIR F SOL_OUT6
11 Brake output (rear wheel) 33806 BK OUTP DIR R SOL_OUT7
12 Retarder lever 33900 RETARD LEVER A_IN_4
13 Body positioner 34602 BODY POSITION A_IN_5
14 Dum lever (hoist lever) potentiometer 34304 DUMP LEVER 1 A_IN_3

1
15 Dump lever (hoist lever) potentiome- 34305 DUMP LEVER 2 A_IN_7
ter 2
16 Hoist EPC output 45600 HOIST EPC DIR SOL_OUT10A
17 Seating control command (Hi) 45102 S CNT DIR H
18 Seating control command (Lo) 45103 S CNT DIR L
Seating condition calibration value

19 45201 S CAL A
( )
Cylinder stopper calibration value
20 45301 S CAL B
( )
21 Seating control time (Hi) 45402 S CNT TIME H
22 Seating control time (Lo) 45403 S CNT TIME L

SOL_OUT10B
23 Shutoff valve output 45700 SHUT OFF VALVE
Converted angle of steering angle sensor
24 Steering position sensor 35402 STRG ANGLE
(A_IN_6) is output.
A_IN_6
25 Steering position sensor 35400 STRG ANGLE
26 PLS_IN0
Steering speed 35403 STRG ANGLE SPEED
Steering speed is output.
Converted pressure of suspension pressure sen-
27 Suspension pressure (left) 32814 SUS PRESS (L) sor (A_IN_10) is output.
Suspension pressure (left) 32815 SUS PRESS (L) A_IN_10

28
Suspension pressure (right) 32816 SUS PRESS (R) Converted pressure of suspension pressure sen-
29 sor (A_IN_9) is output.
30 HD465-7E0, HD605-7E0
Data range Remarks

Depending upon software part number
0.00 – 5.00 [V]

---- [ARSC setting OFF or other than above]
0 – 32767 [rpm]
---- [ARSC option setting OFF or other than above]
0 – 32767 [rpm]
0 – 32767 [rpm]
0 – 160 [°C]
0.00 – 5.00 [V]
0 – 1000 [mA] [command value]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.0 – 10.00 [s]
Down to 2 decimal places are displayed.
0.0 – 10.00 [s]
ON [1]
Unit is not displayed.
OFF [0]
-180.0 – +180.0 [°]
0.00 – 5.00 [V]
0.0 – 99.99 [rad/s]
0.00 – 20.10 [MPa]
---- [Automatic suspension option setting OFF and ARSC option
setting OFF, or other than above]
0.00 – 5.00 [V]
0.00 – 20.10 [MPa]
HD465-7E0, HD605-7E0 31

Suspension pressure (right) 32817 SUS PRESS (R) (A_IN_9)
30
Judgment of empty/loaded truck 39400 EMPTY OR LOAD Judgment of empty/loaded truck is output.
31
ASR output (L) command 39601 ASR OUTP DIR L Output command value to ASR (L) solenoid is out-
32
put.
33 ASR output (R) command 39603 ASR OUTP DIR R Output command value to ASR (R) solenoid is
output.
34 Input signal D_IN_0--7 40932 D-IN--0-----7 Input signal stats of D_IN_0 – D_IN_7 are output
as they are.
35 Input signal D_IN_8--15 40933 D-IN--8-----15 Input signal stats of D_IN_8 – D_IN_15 are output
as they are.
Input signal stats of D_IN_16 – D_IN_23 are out-

put as they are.
36 Input signal D_IN_16-23 40934 D-IN-16-----23

put as they are.

put as they are.
D_OUT_0 – 7 refer to SOL_OUT_0 – 7 of CR710.
39 Output signal D_OUT_0-7 40955 D-OUT-0-----7
D_OUT_8 – 15 refer to SOL_OUT_8, 9, 10A, 10B,

11A, 11B, SIG_OUT_0 and SIG_OUT_1 of
40 Output signal D_OUT_8-15 40956 D-OUT-8-----15 CR710.
41 Output signal D_OUT_16-23 40957 D-OUT-16-----23 D_OUT_16 – 23 refer to SIG_OUT_2, 3,

HSW_OUT_0, 1 and BATT_RY_OUT of CR710.
D_OUT_21, 22 and 23 are not used.
32 HD465-7E0, HD605-7E0
Data range Remarks

0.00 – 5.00 [V]
LOAD [1]
EMPTY [0] Unit is not displayed.
Command value 0 – 1020 [mA] [00 – FF]
Command value 0 – 1020 [mA] [00 – FF]
01010101 ["1.0" is displayed under corresponding display (num-
ber)]
Input signal ON [1], Unit is not displayed.
Input signal OFF [0],
"0" is displayed on unused part.
01010101 ["1.0" is displayed under corresponding display (num- Unit is not displayed.
ber)]
Input signal ON [1],
ber)]
ber)]
ber)]
ber)]
ber)]
ber)]
HD465-7E0, HD605-7E0 33
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.
34 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 35
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.
36 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 37
Battery disconnector switch 1

EU spec.
38 HD465-7E0, HD605-7E0
With VHMS
1. Battery box
2. Battery disconnect switch
3. Diode (With VHMS)
Disconnect and jump start electrical circuit diagram

(For STD battery)
HD465-7E0, HD605-7E0 39
Large battery spec.
40 HD465-7E0, HD605-7E0
With VHMS
1. Battery box (Main)

2. Battery box (Sub)
3. Battery disconnect switch
4. Diode (With VHMS)

(For large battery)
HD465-7E0, HD605-7E0 41

(For VHMS)
42 HD465-7E0, HD605-7E0
Function
When the option "battery disconnect switch" is
equipped
q When the battery disconnect switch is equipped
and the switch is OFF (the contact is opened),
the starting switch B terminal, respective con-
trollers, and other constant power supplies are
all cut out, and the state is the same as when
the battery is not connected.
q The battery disconnect switch is usually used
for substitution to take off the minus terminal of
the battery, when the machine is stored for a
long time (a month or longer), when the electri-
cal system is repaired, or when electrical weld-
ing is performed.
When the battery disconnect switch is turned off, all
the electrical system of the machine will be inopera-
tive.
q The clock of the monitor/radio and reception
preset memory of radio will be lost, and need
to be set again when using them.
q Such functions as room lamp, step lamp, and
hazard lamp cannot be used either.
q Since VHMS is saving data with battery power
immediately after the starting switch is turned
off, when turning the battery disconnect switch
off, ensure that the VHMS operation indicator
(inside switch box) has gone out. If it is turned
off before the indicator goes out, a cycle of
VHMS data, from the time the starting switch is
turned on to the time when it is turned off, will
be lost. (Information necessary to set the
machine will not be lost)
k Important
Do not turn off the battery disconnect switch
while the engine is rotating and immediately
after the engine has stopped.
If the battery disconnect switch is turned off
while the alternator is generating electricity, the
generated current has nowhere to go, leading
to overvoltage of the electrical system of the
machine, which may cause serious damage to
the electrical system such as electric devices
or controllers.
HD465-7E0, HD605-7E0 43
Dump control lever 1
44 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 45
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.
46 HD465-7E0, HD605-7E0
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 FLOAT position.
HD465-7E0, HD605-7E0 47

© 2009 KOMATSU
All Rights Reserved
48 HD465-7E0, HD605-7E0
SEN01098-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Payload meter (Card type) .......................................................................................................................... 2
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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".
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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°)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.)
HD465-7E0, HD605-7E0 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
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Mass on spring (empty) t (Metric ton)
g) Load mass calculation data (analog data)

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

Month Month 1-12
Day Day 1-31
Time Hour Hour 0-23
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Mass on spring (front) t (Metric ton) 0-6553.5
Mass on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Mass on spring (empty) t (Metric ton)
(Calibration value)
0.7500 –1.2500
Trimmer gain value Integer
0-6553.5
Load mass t (Metric ton)
0-25.5
Backup battery voltage V
The above data items a) – g) are retained even when the power is switched OFF.
14 HD465-7E0, HD605-7E0
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 (%)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 17
18 HD465-7E0, HD605-7E0
(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:
XXX.X
8 x 98kPa P'RR (Rear right)
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
(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".
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
( 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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
( 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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 31

© 2007 KOMATSU
All Rights Reserved
32 HD465-7E0, HD605-7E0
SEN01099-05
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

VHMS controller related.................................................................................................................................. 2
ASR system (If equipped) ............................................................................................................................. 26
Sensors, switches ......................................................................................................................................... 32
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 3
Payload meter (having VHMS)

System configuration
4 HD465-7E0, HD605-7E0
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".
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)".
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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 measure-
ous screen appears. ment.
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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: 1 bit
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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] [3] [4] ETX (03h) BCC
[1]:
P (ASCII) fixed
[2]:
4 (ASCII) fixed
[3]:
02 (h) fixed (Unit classification [HEX])
[4]:
Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
Order: Lower position upper position from the head byte of [4]

or
22 HD465-7E0, HD605-7E0

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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

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
HD465-7E0, HD605-7E0 25
ASR system (If equipped) 1

ASR specification
26 HD465-7E0, HD605-7E0
1. Brake system tank

2. Torque converter, transmission, transmission
lubrication, brake cooling, brake control pump
(SDR(30)100+SA(1)25)
3. ASR control valve
4. ASR shut-off valve
5. Steering angle sensor
6. Wheel speed sensor
7. ASR oil pressure switch
HD465-7E0, HD605-7E0 27
System operation logic
Outline
ABS (Anti-skid Brake System) ASR (Automatic Spin Regulator)
q The ABS automatically controls slippage that is q The ASR prevents the drive wheels from slip-
caused by locking of the wheels when the ping when there is excessive torque. In this
brakes are applied suddenly or on snow or way it improves the starting ability and drive-
other slippery road surfaces. In this way, the through ability on poor or frozen road surfaces.
ABS keeps the machine stable and insures q When the machine starts to move on snow-
that it can be steered. covered or split road surfaces (where the con-
q With the ABS, the ABS controller calculates dition of the road surface is different on the left
the machine travel speed and the speed of and right: such as when one side is snow and
each wheel from the signals sent by the wheel the other side is dry road), if an excessive
speed sensors installed to each wheel. It then torque is applied to the wheels, both or one of
sends a signal to the pressure control valve for the wheels will spin and it may be impossible
the wheel where the brakes may possibly for the machine to start. However, if the
lock, thereby controlling the brakes on the four machine is equipped with an ASR, the brake is
wheels independently. automatically applied to the wheel that is spin-
ning and the torque applied to the wheel is
a When the ABS is actuated on a slippery road controlled, so the machine can move off.
surface, the braking distance becomes slightly
longer. a If both rear wheels slip at the same speed, the
a When traveling at extremely low speed, the ASR function is not actuated, so reduce the
wheels may lock. pressure on the accelerator to control the
engine output.
28 HD465-7E0, HD605-7E0
ASR (Automatic spin regulator)
Operation
When ASR does not operate
q While the vehicle is travelling normally and the
speeds of both rear wheels are not much dif-
ferent from each other, ASR does not operate
and the brake is not applied to the drive
wheels.
q When the vehicle turns, ASR still does not
operate since the condition for starting the con-
trol changes according to the steering angle.
ASR will operate if the vehicle turns on a slip-
pery road and the speeds of the drive wheels
become greater from each other than what
they should at a given steering angle.
When ASR operates (When vehicle starts)

q If the speeds of both drive wheels become dif-
ferent from each other while the accelerator
pedal is depressed as shown in the graph, the
slipping wheel is braked so that the speeds of
both wheels will be the same.
HD465-7E0, HD605-7E0 29
ASR control valve
1. Filter Function
2. Connector q The ASR control valve is installed between the
3. Solenid assembly accumulator and slack adjuster. It changes the
discharge oil pressure to control the braking
A: To slack adjuster force according to the ASR control electric out-
P: From accumulator put from the retarder controller.
30 HD465-7E0, HD605-7E0
ASR shut-off valve
2. Solenoid q The ASR shut-off valve is installed between
the accumulator and ASR control valve.
A: To ASR control valve q If the ASR switch is turned ON, the solenoid
P: From accumulator valve is energized to make the ASR hydraulic
T: To brake system tank circuit effective.
q If the ASR switch is turned OFF, the solenoid
valve is de-energized to make the ASR
hydraulic circuit ineffective.
HD465-7E0, HD605-7E0 31
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.
32 HD465-7E0, HD605-7E0
Accelerator sensor
HD465-7E0 Serial No. 10001 – 10037, 10101 – 10204
HD605-7E0 Serial No. 8001 – 8032, 10101 – 10201
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.
HD465-7E0, HD605-7E0 33
HD465-7E0 Serial No. 10205 –

HD605-7E0 Serial No. 10202 –
1. Pedal 3. Sensor
2. Connector
Function
• This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle val-
idation signal depending on the accelerator Output characteristics
pressing angle.
Accelerator signal
• Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer in-
side the sensor is output in variable voltage from
No. 2 pin.
Idle validation signal

• The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator pedal
is released, it outputs the signal being entered
to No. 5 pin from No. 4 pin. And as the acceler-
ator pedal is pressed, it outputs the signal being
entered to No. 6 pin from No. 4 pin.
34 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 35
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.
36 HD465-7E0, HD605-7E0
Fuel level sensor
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.
HD465-7E0, HD605-7E0 37
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
38 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 39
Body positioner sensor
Steering angle sensor (for ASR)
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.
q The steering angle sensor is installed to the
center lever and transmits voltage signals to
the controller according to the center lever
angle.
40 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 41
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
42 HD465-7E0, HD605-7E0
ASR oil pressure switch
1. Switch Function
2. Tube q The ASR oil pressure switch is installed to
3. Connector brake assembly.
HD465-7E0, HD605-7E0 43
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.
44 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 45
Weel speed sensor (For ASR)
1. Spring spacer Function

2. Tube q This is non-condact sensor. A pulse voltage is
3. Connector generated by rotation of the teeth of the gear
installed to the outside of the pulse wheel, and
a signal is sent to the controller.
46 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 47
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
48 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 49
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
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 51

© 2009 KOMATSU
All Rights Reserved
52 HD465-7E0, HD605-7E0
SEN01649-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 4
HD465-7E0, HD605-7E0 1
SEN01649-03 20 Standard value table
Standard value table for engine 1

Machine model HD465-7E0, HD605-7E0
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. 160 Min. 147
(Boost pressure) • Power train oil temperature: Within oper- {mmHg} {Min. 1,200} {Min. 1,100}
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. 12.29
sure • Power train oil temperature: Within oper- {mmH2O} {Max. 350} {Max. 1,320}
ating range
• When torque converter is stalling
[*] Condition for stationary mode:

Set the transmission shift lever in the "N" position and apply the parking brake "PARKING" and set the
hoist lever in the "FLOAT" position.
2 HD465-7E0, HD605-7E0
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 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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

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
Economy mode (Loaded: *1)
F3 o F4
F4 o F5 1,935 ± 50 1,935 ± 50
Accelerator full
• Engine coolant tempera-

F5 o F6
Engine speed

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- 1,350 ± 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
*1: The truck is recognized to be loaded when the rear suspension gas pressure is 9.8 MPa {100 kg/cm²} or
higher (The load is about 137.3 kN {14 ton} or more).
HD465-7E0, HD605-7E0 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: *2)
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
*2: The truck is recognized to be unloaded when the rear suspension gas pressure is below 9.8 MPa {100
kg/cm²} (The load is below about 137.3 kN {14 ton} or more).
6 HD465-7E0, HD605-7E0

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 1,550 ± 50 1,550 ± 50
F1 o F2
F2 o F3
Shift up
F3 o F4 rpm
2,450 ± 50 2,450 ± 50
F4 o F5
Braking mode
F5 o F6
F6 o F7
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 • Engine coolant tempera- 1,300 – 1,500 1,300 – 1,500
Auto lock-up
Set
Engine speed
F3 – F7 ture: Within operating 1,250 – 1,500 1,250 – 1,500

range
F1, F2 • Transmission oil tempera- 1,100 1,100
Reset
F3 – F7 ture: 60 – 80 °C 1,050 1,050
• Hydraulic oil tempera-
Low speed mode 1
F1 – F5, R ture: 45 – 55 °C 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
Reset F1 – F7, R rpm 2,300 2,300
F1, F2, F7, R 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
alarm Reset F1 – F7, R 2,300 2,300
HD465-7E0, HD605-7E0 7

Power mode • Engine coolant tempera- 1,910 ± 100 1,910 ± 100

range
High load
• Transmission oil tempera- rpm 1,860 ± 100 1,860 ± 100
Economy (*3)
ture: 85 – 110 °C
mode Low load • Hydraulic oil tempera-
ture: 45 – 55 °C 1,820 ± 100 1,820 ± 100
(*4)
• Engine cool-
ant tempera-
ture: Within
operating
range A mode
1,910 ± 100 1,910 ± 100
• Transmis- (*5)
sion oil tem-
perature: 85
Engine speed
– 110 °C
Torque • Hydraulic oil
converter temperature:
speed 45 – 55 °C
a For details of
At inspection with engine the engine
B mode
mode fixing function set mode fixing rpm 1,860 ± 100 1,860 ± 100
(*5)
by machine monitor function, see
Testing and
adjusting,
"Special
functions of
machine
monitor
(EMMS), [18]
Engine mode C mode
1,820 ± 100 1,820 ± 100
(*5)
fixing func-
tion (FIX
POWER
MODE)".
*3: Means that the truck is loaded (The rear suspension gas pressure is 9.8 MPa {100 kg/cm²} or higher
(The load is about 137.3 kN {14 ton} or more)).
*4: Means that the truck is unloaded (The rear suspension gas pressure is below 9.8 MPa {100 kg/cm²}
(The load is below about 137.3 kN {14 ton} or more)).
*5: Details of each mode (When mode A – C is selected, the following is set)
Mode setting Condition (*) Rated output High idle speed
Mode A Power mode When loaded/When unloaded 552 kW {740 HP}/2,000 rpm 2,270 rpm
Mode B Economy mode High load condition (When loaded) 524 kW {703 HP}/2,000 rpm 2,270 rpm
Mode C Economy mode Low load condition (When unloaded) 500 kW {670 HP}/1,900 rpm 2,200 rpm
*: Remarks
q When loaded: When the rear suspension gas pressure is ensured to be 9.8 MPa {100 kg/cm²} or
higher (the load is about 137.3 kN {14 ton} or more), the truck is recognized to be loaded.
q When unloaded: When the rear suspension gas pressure is ensured to be below 9.8 MPa {100 kg/cm²}
(the load is below about 137.3 kN {14 ton}), the truck is recognized to be unloaded.
8 HD465-7E0, HD605-7E0

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)}
farce • 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}
farce Do6 {kg}
• At center of 6o5
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 7E0) • 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}
7E0) wheel)
HD465-7E0, HD605-7E0 9

Stop slope angle
• With 55 t payload
(HD465-7E0)
• With 63 t payload °
Braking capacity 11.5 11.5
(HD605-7E0) (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 load surface
Front • When unloaded 249 ± 10 249 ± 20
• Dimension see Fig. 1 in
Dimension
Installed "A"
mm
length • On flat dry load 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-
7E0) 2.31 ± 0.24 2.31 ± 0.24
Rear
Pressure
• On flat dry load 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-
7E0) 2.62 ± 0.26 2.62 ± 0.26
Rear
{26.8 ± 2.7} {26.8 ± 2.7}
Stationary steering effort • On flat dry load 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 HD465-7E0, HD605-7E0

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

force
Operating force
{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

force
Operating force • 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

force
Operating force
{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 (atmosphere tempera-
service brake {kg/cm²} {63 ± 2.0} {63 ± 2.0}
pressure ture): 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)}
HD465-7E0, HD605-7E0 11

• Dry flat road When

Max. 17.0 Max. 17.0
• At max. unloaded
brake opera-
HD465-7E0
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
HD605-7E0 • 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-
HD465-7E0 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
HD605-7E0 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
(HD465-7E0)
• With 63 t payload
(HD605-7E0)
Servise brake • Empty machine 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 start at Max. 1,670 Max. 1,670
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 HD465-7E0, HD605-7E0

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 force
Operating force
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 of exten-

sion 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
HD465-7E0, HD605-7E0 13

© 2008 KOMATSU
All Rights Reserved
14 HD465-7E0, HD605-7E0
SEN01650-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketch of special tool ...................................................................................................................................... 9
Testing engine speed .................................................................................................................................... 10
Testing air supply pressure (boost pressure) .................................................................................................11
Testing exhaust temperature......................................................................................................................... 12
Testing exhaust gas color ............................................................................................................................. 14
Adjustment of valve clearance ...................................................................................................................... 16
Testing of compression pressure .................................................................................................................. 18
Testing blow-by pressure .............................................................................................................................. 21
Testing engine oil pressure ........................................................................................................................... 22
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 23
Handling of fuel system devices ................................................................................................................... 25
Releasing residual pressure from fuel system .............................................................................................. 25
Testing of fuel pressure................................................................................................................................. 26
Reduced cylinder mode operation ................................................................................................................ 27
No-injection cranking .................................................................................................................................... 27
HD465-7E0, HD605-7E0 1
SEN01650-04 30 Testing and adjusting
Testing of fuel return rate and fuel leakage ................................................................................................... 28

Bleeding air from fuel circuit.......................................................................................................................... 30
Testing the fuel circuit for leakage................................................................................................................. 31
Replacement and adjustment of fan belt....................................................................................................... 32
Replacement and adjustment of alternator and air conditioner compressor belt .......................................... 33
2 HD465-7E0, HD605-7E0
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) Type I, 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 Bosch index: 0 – 9
2 795-502-1350 Smoke meter 1
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: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm²}
1
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Testing engine oil 60 MPa {600 kg/cm²}
pressure Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1 MPa {10 kg/cm²}
799-101-5230 Nipple 1 14 × 1.5 mm
3
G 6215-81-7920 O-ring 1
795T-690-1110 Block 1 Refer to the sketch of special tool
4 01435-00835 Bolt 2
Testing drive oil pressure 07000-E2012 O-ring 3
of EGR valve and bypass Pressure gauge: 2.5, 6, 40, 60 MPa
valve 5 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm²}
Pressure gauge:
6 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm²}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm²}
1
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 60 MPa {600 kg/cm²}
2 799-101-5160 Nipple 1
Pressure gauge:
3 799-401-2320 Gauge 1
1 MPa {10 kg/cm²}
HD465-7E0, HD605-7E0 3
Sym-
Q'ty
bol
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
Oil pressure gauge KIT Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Testing power train oil Oil pressure gauge KIT Pressure gauge:
790-261-1204 1
pressure (Digital) 60 MPa {600 kg/cm²}
799-101-5220 Nipple 1
2 M10 × 1.25
07002-11023 O-ring 1
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Testing brake oil pressure Oil pressure gauge KIT Pressure gauge:
799-261-1204 1
(Digital) 60 MPa {600 kg/cm²}
599-35-43561 Nipple 1 18 × 1.5 (Female: PT 1/8)
K Oil pressure gauge KIT Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 1
Testing steering, hoist oil (Analog) {25, 60, 400, 600 kg/cm²}
1
pressure circuit Oil pressure gauge KIT Pressure gauge:
790-261-1204 1
(Digital) 60 MPa {600 kg/cm²}
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Oil pressure gauge KIT Pressure gauge:
790-261-1204 1
Testing dump EPC oil (Digital) 60 MPa {600 kg/cm²}
pressure circuit 4 799-101-5230 Nipple 1 14 × 1.5
1 Face seal type (# 02)

799-401-3100 Adapter
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
– 792-610-1000 Suspension tool assembly 1
– 792-610-1100 •Pump Ass'y 1
1 792-610-1130 ••Pump 1
2 792-610-1110 ••Hose 1
• L1 to L3 are inner parts of 792-610-
3 792-610-2200 ••Joint 1 1100.
– 792-610-1200 •Charging tool assembly 1 • L4 to L10 are inner parts of 792-
Suspension cylinder of 610-1200.
L 4 07020-21732 ••Fitting 1
adjustment • 792-610-1100 and 792-610-1200
5 792-610-1140 ••Joint 1 are inner parts of 792-610-1000.
6 792-610-1250 ••Valve Ass'y 1 • 792-610-1000 includes tool box
792-610-1290.
7 792-610-1260 ••Nipple 1
8 792-610-1270 ••Hose 2
9 792-610-1280 ••Valve 2
10 792-610-1400 ••Regulator 1
4 HD465-7E0, HD605-7E0
Sym-
Q'ty
bol
At raise and lower of
M 792T-491-1110 Plug 1 Refer to the sketch of special tool
emergency dump body
1 799-608-3211 Discket 1
Initial set up of VHMS con- 2 799-608-3220 Harness 1
N
troller and, at repair set up Commercially Lap top type personal OS: Windows 98/2000/Me/XP
3 1
available computer Terminal "RS232C" is with it
1 792-610-1700 Gas charge tool 1
792-610-1310 Nipple (For Russia) 1 GOST
792-610-1320 Nipple (For USA) 1 CGA No. 351
ASA
792-610-1330 Nipple (For USA) 1
Gas pressure check and B-571-1965
P
filling of the accumulator 2 DIN 477-1963
NEN 3268-1966
792-610-1350 Nipple (For Germany) 1
SIS-SMS
2235/2238
BS341
792-610-1360 Nipple (For UK) 1
Part 1-1962
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, ECONO-60P (Does not
• T-box for DRC60,
799-601-4350 1 include in assembly No.799-601-
ECONO
4201)
For RACKARD-2P (Engine (CRI-T3)
1
coolant temperature sensor)
• Socket for engine (CRI- For RACKARD-2P (Engine (CRI-T3)
795-799-5530 1
T3) fuel temperature sensor)
For RACKARD-2P (Engine (CRI-T3)
1
oil temperature sensor)
• Socket for engine (CRI- For RACKARD-2P (Engine (CRI-T3)
795-799-5540 1
T3) boost temperature sensor)
• Socket for engine (CRI- For AMP-3P (Engine (CRI-T3) ambi-
Diagnosis for engine 799-601-4240 1
T3) ent pressure sensor)
related controller, sensor, –
• Socket for engine (CRI- For SUMITOMO-3P (Engine (CRI-
actuator and harness 799-601-4250 1
T3) T3) boost pressure sensor)
• Socket for engine (CRI- For SUMITOMO-3P (Engine (CRI-
799-601-4330 1
T3) T3) G (Bkup) sensor)
For SUMITOMO-2P (Engine (CRI-
• Socket for engine (CRI-
799-601-9430 1 T3) supply pump PCV1 and PCV2
T3)
sensor)
• T-adapter for engine For FRAMATOME-3P (Engine (CRI-
799-601-4130 1
(CRI-T3) T3) NE sensor)
• T-adapter for engine For FRAMATOME-3P (Engine (CRI-
799-601-4150 1
(CRI-T3) T3) oil pressure sensor)
• T-adapter for engine For AMP-3P (Engine (CRI-T3) com-
799-601-9420 1
(CRI-T3) mon rail pressure sensor)
For DRC-50P (Engine (CRI-T3) con-
• T-adapter for engine
799-601-4211 1 troller) (Does not include in assem-
(CRI-T3) controller
bly No.799-601-4201)
HD465-7E0, HD605-7E0 5
Sym-
Q'ty
bol
For DRC-60P (Engine (CRI-T3) con-
• T-adapter for engine
799-601-4220 1 troller) (Does not include in assem-
(CRI-T3) controller
bly No.799-601-4201)
• T-adapter for engine For DTP-40P (Engine (CRI-T3) con-
799-601-4260 1
Diagnosis for engine (CRI-T3) controller troller)
related controller, sensor, – For DT-4P (Include in assembly
actuator and harness 799-601-9040 • T-adapter for DT 1 No.799-601-9000 and 799-601-
9200, too)
For DT-2P (Include in assembly
799-601-9020 • T-adapter for DT 1 No.799-601-9000 and 799-601-
9200, too)
799-601-2500
or
799-601-2800
or
799-601-7100 T-adapter assembly 1
or
799-601-7400
or
799-601-8000
799-601-2600 • T-box for ECONO 1 For ECONO-21P
For MIC-21P (Include in assembly
799-601-2740 • T-adapter for MIC 1
No.799-601-2700, too)
799-601-4101
799-601-4201
9200, too)
9200, too)
Diagnosis for chassis
related controller, sensor, – For DRC60, ECONO-60P (Does not
• T-box for DRC60,
actuator and harness 799-601-4350 1 include in assembly No.799-601-
ECONO
4201)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For M-1P (Does not include in
799-601-7080 • T-adapter for M 1 assembly No.799-601-7000, 799-
601-7100)
799-601-7090 • T-adapter for M 1 For M-2P
799-601-7170 • T-adapter for S (Blue) 1 For S-16P (Blue)
For SWP-8P (Does not include in
799-601-7060 • T-adapter for SWP 1
assembly No.799-601-8000)
799-601-7020 • T-adapter for X 1 For X-2P
6 HD465-7E0, HD605-7E0
Sym-
Q'ty
bol
799-601-9000
799-601-9100
799-601-9250 • T-adapter for HD30/24 1 For HD30/24-9P
For ECONO-24P (Include in assem-
799-601-9320 • T-box for ECONO 1
bly No.799-601-9300, too)
799-601-9000
799-601-9200
799-601-9030 • T-adapter for DT 1 For DT-3P
799-601-9050 • T-adapter for DT 1 For DT-6P
799-601-9060 • T-adapter for DT (Gray) 1 For DT-8P (Gray)
• T-adapter for DT
799-601-9070 1 For DT-8P (Black)
(Black)
799-601-9080 1 For DT-8P (Green)
(Green)
799-601-9090 1 For DT-8P (Brown)
(Brown)
Diagnosis for chassis 799-601-9110 • T-adapter for DT (Gray) 1 For DT-12P (Gray)
actuator and harness 799-601-9120 1 For DT-12P (Black)
(Black)
799-601-9130 1 For DT-12P (Green)
(Green)
799-601-9140 1 For DT-12P (Brown)
(Brown)
799-601-7180 • T-adapter for AMP040 1 For AMP040-8P
799-601-7510 • T-adapter for 070 1 For 070-10P
799-601-7330 • T-adapter for S (White) 1 For S-16P (White)
799-601-9360 • T-adapter for DRC 1 For DRC-24P (Pump controller)
799-601-9350 • T-adapter for DRC 1 For DRC-40P (Pump controller)
Out of kit (No assembly No.)
799-601-7320 T-adapter for SWP 1 For SWP-16P
799-601-7340 T-adapter for M 1 For M-8P
HD465-7E0, HD605-7E0 7
Sym-
Q'ty
bol
Diagnosis for chassis 799-601-7360 T-adapter for RELAY 1 For REL-5P
actuator and harness 799-601-7370 T-adapter for RELAY 1 For REL-6P
Testing coolant tempera-

– 799-101-1502 Digital temperature gauge 1 -99. 9 – 1,299 °C
ture and oil temperature
Testing operation effort – 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
and pedal effort – 79A-264-0091 Push-pull scale 1 0 – 490 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
– Circuit tester 1
tance available
8 HD465-7E0, HD605-7E0
Sketch of special tool 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these draw-
ings.
G4 Block
M Plug
HD465-7E0, HD605-7E0 9
Testing engine speed 1

k Stop the machine on flat ground, turn the
parking brake switch PARKING, and block
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 shift lever "N" and dump lever in
HOLD.
2) Start the engine and measure the engine
speed without pressing the accelerator
pedal.
3. Testing high idle speed

1) Set the shift lever "N" and dump lever in
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)".
10 HD465-7E0, HD605-7E0
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
chocks to the tires.
k Be careful not to touch any hot parts when
removing or installing 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.
under the following conditions.
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 a mid-range speed or above
to bleed the oil from the hose.
a Insert the connection of the hose and
pressure gauge about half way, repeat the
action to open the self-seal portion at the
hose end, and bleed the oil.
a If Pm kit 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 test the air supply pressure
(boost pressure).
a For details of the procedure for stalling the
torque converter, see "Testing torque con-
a For the method of testing, see "Method verter stall speed".
with testing instruments".
6. After completing the testing, rermove the test-
(Method with testing instruments) ing equipment and set to the original condition.
1. Open the engine hood.
2. Remove air supply pressure testing plug (1).
HD465-7E0, HD605-7E0 11
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 removing or
installing 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 testing plug (1)
from the exhaust manifold. 4. Method of periodic testing for preventive main-
a Test at each of the front and rear plugs. 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 gearshift lever is operated to
3. Install sensor [1], then connect to digital tem- any position other than the D posi-
perature gauge B. tion, the machine may move off
a Clamp the wiring harness of the sensor [1] even if the brake is being
gauge at a suitable place to prevent it from depressed, so always test at the D
touching any hot part. position.
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.
12 HD465-7E0, HD605-7E0
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 outside air 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".
HD465-7E0, HD605-7E0 13
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
2 795-502-1350 Smoke meter

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

1) Raise the body and fix it with the lock pin 3) Connect the probe hose, receptacle of the
securely. accelerator switch, and air hose to smoke
2) Attach a sheet of filter paper to handy meter C2.
smoke checker C1. a Restrict the supplied air pressure
3) Insert the exhaust gas intake pipe in below 1.5 MPa {15 kg/cm²}.
exhaust pipe (1). 4) Connect the power cable to a receptacle
4) Start the engine and raise the temperature of power source.
of the engine to the operating range. a Before connecting the cable, check
5) As increasing the engine speed rapidly or that the power switch of the smoke
running it at high idle, operate the handle meter is turned off.
of handy smoke checker C1 so that the fil- 5) Loosen the cap nut of the suction pump
ter paper absorbs the exhaust gas. and fit the filter paper.
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.
14 HD465-7E0, HD605-7E0
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, press the accelera-
tor 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.
HD465-7E0, HD605-7E0 15
Adjustment of valve clearance 1

Commercially
D Thickness gauge
available


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 arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. 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 cranking device (7) at the
a Loosen locknut (11) of adjustment screw
rear of the left side of the engine and crank the
(10) and insert thickness gauge D
engine, pressing shaft (9).
between crosshead (12) rocker arm (13)
a The upper part of the figure is the rear part
and set adjustment screw (10) to a degree
of the engine.
that you can move the thickness gauge
lightly.
a Standard valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
16 HD465-7E0, HD605-7E0
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 clearances marked with Q in
the valve arrangement drawing.
a Adjust the valve clearances 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}
HD465-7E0, HD605-7E0 17
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 in hole (a) of adapter
take care not to burn yourself on the ex- (10) and move the weight of tool E3 up
haust manifold, muffler, etc. or get caught 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).
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.
18 HD465-7E0, HD605-7E0
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) and

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

test 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) While setting adapter (10) to injector (9),
push them into the cylinder head.
HD465-7E0, HD605-7E0 19
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}
aTighten the cylinder head cover mounting

bolt 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}
20 HD465-7E0, HD605-7E0
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)

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.
2. Start the engine and raise the temperature of q Monitoring code: 42801 (BLOWBY PRESS)
the coolant to the operating range. a For the operating method, see "Special
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 operated to any
position other than the D position, the
machine may move off even if the
brake is being depressed, so always
check 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 There is danger of damage to the inter- a For details of the method of testing, see
nal parts of the transmission, so never "Method using testing equipment".
operate the gearshift lever to any posi-
tion other than the D position during
the stall operation.
HD465-7E0, HD605-7E0 21
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 type hydraulic tester
Hydraulic tester
G 2 790-401-2320
(1 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.

22 HD465-7E0, HD605-7E0
Testing EGR valve and bypass 3. Install EGR valve drive oil supply tube (1) to
the top of tool G4 and tighten flange mounting
valve drive oil pressure 1 bolts (2) on the EGR valve side.
3 Flange mounting bolt (2):
a Testing instruments for EGR valve and bypass
valve drive oil pressure 27 – 34 Nm {2.8 – 3.5 kgm}

795T-690-1110 Block
4 01435-00835 Bolt
G 07000-E2012 O-ring
5 799-101-5002 Hydraulic tester
6 790-261-1204 Digital hydraulic tester
1. Remove flange mounting bolts (2) of EGR

valve drive oil supply tube (1) on the EGR
valve side and clamp mounting bolts (3).
4. Install the nipple (component part of G5) to

measuring hole (a) (size: PT 1/8) of tool G4
and connect hydraulic tester G5.
Reference: Since the maximum oil pressure to
be measured will be about 3 MPa {30 kg/cm2},
select a proper pressure gauge in the kit.
2. Install tool G4 to the EGR valve oil supply

area.
3 Mounting bolt (4) (component part of
G4): 27 – 34 Nm {2.8 – 3.5 kgm}
HD465-7E0, HD605-7E0 23
5. Run the engine and measure the oil pressure

at low idle and high idle.
6. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
a Replace the flange O-ring on the EGR
valve side with new one.
3 Flange mounting bolt (2):
27 – 34 Nm {2.8 – 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 – 73.5 Nm {6 – 7.5 kgm}
24 HD465-7E0, HD605-7E0
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.)
HD465-7E0, HD605-7E0 25
Testing of fuel pressure 1 4. Install fuel and air bleeder piping (1) again.
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
H
2 799-101-5160 Nipple
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 5. Run the engine and test the fuel pressure at
high-pressure circuit from the supply pump high idle.
through the common rail to the injector, it a If the fuel pressure is in the following stan-
cannot be measured. dard range, it is normal
the parking brake switch PARKING, and set Engine speed Fuel pressure
chocks to the tires. Min. 0.15 MPa
High idle
{1.5 kg/cm²}
1. Remove the cover in the left front fender.
2. Remove fuel air bleeder piping (1) and remove

fuel pressure pickup plug (2) from the top of
the fuel filter.
6. After finishing testing, remove the testing in-

struments and return the removed parts.
3. Install elbow [1] and nipple [2] of hydraulic tes-

ter H1 and connect them to gauge H3.
26 HD465-7E0, HD605-7E0
Reduced cylinder mode operation1 No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the en-
run the engine with the fuel injectors of 1 or gine with the starting motor while all the injec-
more cylinders disabled electrically to reduce tions are stopped electrically. The purpose
the number of effective cylinders. The purpos- and effect of this operation are as follows.
es 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 normal
operation (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)".
HD465-7E0, HD605-7E0 27
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) Insert joint J2 on common rail (1) side and
available
tighten the removed joint bolt again.
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 (3) between common rail (1)
and supply pump (2).
4) Insert spacer J1 on block (2) 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.
28 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 29
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
off and the electric priming pump stops.
k
replaced
a If the fuel filter was replaced, do not fill the While the electric priming pump is op-
main filter and prefilter with the fuel. eration, 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 circuit valve.
5. After the specified time (approx. 7 minutes),

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

is completed.
8. Turn lever (1) of the air bleeding piping to the

vertical position to close the circuit valve.
30 HD465-7E0, HD605-7E0
9. Start the engine with the starting motor. Testing the fuel circuit for leakage1
k When starting the engine, check that
k Very high pressure is generated in the high-
there is no person around it.
a Do not operate the starting motor continu- pressure circuit of the fuel system. If fuel
ously for more than 20 seconds. leaks while the engine is running, it is dan-
q After starting the engine, run it at low gerous since it can catch fire.
idle for about 5 minutes to bleed all air a After testing the fuel system or removing and
from the fuel circuit. installing its components, check for fuel leak-
q Stop the engine and check that the air age according to the following procedure.
bleeding valve is closed.
1. Spray color checker (developer) over the sup-
10. If the engine does not start, try to start it again
ply pump, common rail, injector, and joints of
according to the following procedure.
the high-pressure piping.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
2. Run the engine at a speed less than 1,000 rpm
ing valve after step 7.)
and stop it after its rotation is stabilized.
a After the engine fails to start, wait for
about 2 minutes before trying to start
3. Check the fuel piping and the devices for fuel
again.
leakage.
1) Turn the electric priming pump switch ON. a Check the high-pressure circuit parts con-
2) While the electric priming pump is operat- centrating on the areas coated with the
ing, crank the engine. color checker, for fuel leakage.
q If the engine does not start, repeat the a If any fuel leakage is detected, repair it
above operation. and test again from step 1.
a Do not operate the starting motor continu-
ously for more than 20 seconds. 4. Run the engine at low idle.
a If the engine fails to start, wait for about 2
minutes and try to start again. 5. Check the fuel piping and the devices for fuel
3) After starting the engine, run it at low idle leakage.
for about 5 minutes to bleed all air from a Check the high-pressure circuit parts con-
the fuel circuit. centrating on the areas coated with the
4) Stop the engine and check that the air color checker, for fuel leakage.
bleeding valve is closed. a If any fuel leakage is detected, repair it
5) After the above operation, start the engine and test again from step 1.
normally.
6. Run the engine at high idle.

leakage.
a Check the high-pressure circuit parts con-
centration 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.
8. While keeping the engine speed at high idle,

apply a load to the engine by stalling the
torque converter or relieving the oil from the
hydraulic pump.

leakage.
a Check the high-pressure circuit parts con-
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.
HD465-7E0, HD605-7E0 31
Replacement and adjustment of 6. After tension pulley (7) moves in, replace fan
belt (8).
fan 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 in bracket (5) to set the inside of the tighten locknut (1).
engine up and fix it with bolt (4). 4) Tighten bolts (3) and (4) to fix bracket (5).
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.
32 HD465-7E0, HD605-7E0
Replacement and adjustment 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).
HD465-7E0, HD605-7E0 33

© 2009 KOMATSU
All Rights Reserved
34 HD465-7E0, HD605-7E0
SEN01651-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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 ........................................................................................................................... 19
Bleeding air from brake circuit ...................................................................................................................... 21
Testing wear of front brake pad..................................................................................................................... 22
Testing wear of rear brake disc ..................................................................................................................... 23
Method of releasing parking brake in an emergency .................................................................................... 24
Testing and adjusting front suspension cylinder ........................................................................................... 25
Testing and adjusting rear suspension cylinder ............................................................................................ 29
Testing and adjusting front suspension cylinder (Automatic suspension specification) ................................ 33
Testing and adjusting hydraulic pressure in steering, hoist circuit ................................................................ 34
Testing and adjusting oil pressure in dump EPC circuit ................................................................................ 37
HD465-7E0, HD605-7E0 1
Air bleeding from steering cylinder................................................................................................................ 38

Procedure for raising dump body in emergency ........................................................................................... 39
Procedure for lowering dump body in emergency......................................................................................... 40
Adjusting body positioner sensor .................................................................................................................. 42
Handling of voltage circuit of engine controller ............................................................................................. 43
Adjusting transmission controller .................................................................................................................. 43
Method for emergency escape at electrical system failure ........................................................................... 44
2 HD465-7E0, HD605-7E0
Testing torque converter stall 5. When the torque converter oil temperature
goes above 90 °C, run the engine immedi-
speed 1 ately at low idle and return the gear shift lever
k Stop the machine on the level ground, turn to the N position.
k
chocks to the tires. Never operate the gear shift lever with
the accelerator pedal depressed. Oth-
erwise it may create a large shock and
1. Turn the starting switch ON and set the monitor
may also become the cause of shorten-
panel in the real-time monitoring function
ing the machine's service life.
(REAL-TIME MONITOR) of the service mode.
q Monitoring functions: 2 ITEMS
q Monitoring code 1: 01002 (ENG SPEED) 6. Run the engine at a medium speed, and when
q Monitoring code 2: 30100 (T/C OIL TEMP) the torque converter oil temperature goes
a For the operation method, see "Special down to approx. 80 °C, run at low idle.
functions of machine monitor". a Keep the gear shift lever at the "N" posi-
tion.
7. Repeat Steps 3 – 6 and equalize the oil tem-

perature in the torque converter and transmis-
sion.
8. At the same time as repeating Steps 3 and 4,

inspect the stall speed when the torque con-
verter oil temperature is 80 °C.
a Inspect the stall speed 2 or 3 times.
a The stall speed may vary according to the
following conditions, so always inspect the
stall speed at the time of delivery.
1) Variations according to the engine se-
2. Start the engine and raise the temperature of rial number
the torque converter oil and hydraulic oil. 2) Variations due to atmospheric pres-
q Torque converter oil temperature: sure and temperature
60 – 80 °C 3) Variations due to the torque con-
q Hydraulic oil temperature: 45 – 55 °C sumed by accessories
4) Variations due to characteristics of
3. Turn the parking brake switch ON, depress the the torque converter
brake pedal, then set the gear shift lever to the 5) Variations due to the method of in-
D position. spection
k If the gearshift lever is operated to any

position other than the D position, the
machine may move off even if the
brake is being depressed, so always
inspect at the D position.
4. Depress the accelerator pedal gradually, run

the engine at high idle and stall the torque con-
verter to raise the torque converter oil temper-
ature.
k There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gear shift lever to any posi-
tion other than the D position during
the stall operation.
HD465-7E0, HD605-7E0 3
Testing power train oil pressure 1
a Testing instrument a Table of oil pressure testing port positions

and gauges to use
Use a gauge
799-101-5002 Analog hydraulic meter No. Testing location (MPa{kg/cm²})
1
790-261-1204 Digital hydraulic meter 1 Main relief pressure 6{60}
K
799-101-5220 Nipple 2 Torque converter inlet port pressure 2.5{25}
2
07002-11023 O-ring 3 Torque converter outlet port pressure 2.5{25}
4 Torque converter lock-up clutch pressure 6{60}
5 Transmission Lo clutch pressure 6{60}
6 Transmission Hi clutch pressure 6{60}
7 Transmission 1st clutch pressure 6{60}
8 Transmission 2nd clutch pressure 6{60}
9 Transmission 3rd clutch pressure 6{60}
10 Transmission 4th clutch pressure 6{60}
11 Transmission R clutch pressure 6{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 HD465-7E0, HD605-7E0
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, stop the engine. 3) Remove plug (2), install nipple K2 and
k When removing and installing a plug or a connect oil pressure gauge [1] (2.5 MPa
testing instrument, stop the engine and {25 kg/cm²}) of hydraulic tester K1 by
wait until the oil temperature lowers thor- hose [2].
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) Heighten 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] (6 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.
HD465-7E0, HD605-7E0 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] (6 MPa {60
connect oil pressure gauge [1] (2.5 MPa kg/cm²}) of hydraulic tester K1 by hose [2].
{25 kg/cm²}) of hydraulic tester K1 by
hose [2].
3) Lower the body to the normal position.

4) Run the engine and heighten the torque
4) Start the engine and test the oil pressure converter oil temperature to the operating
at high idle. range.
5) After finishing testing, remove the testing 5) Turn the parking brake switch to the "OFF"
instruments and return the removed parts. position. While pressing 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 HD465-7E0, HD605-7E0
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] (6 MPa {60
R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R kg/cm²}) of hydraulic tester K1 by hose [2].
QQQQQQ F1 w q
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.
HD465-7E0, HD605-7E0 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] (6 MPa {60 connect oil pressure gauge [1] (6 MPa {60
kg/cm²}) of hydraulic tester K1 by hose [2]. kg/cm²}) of hydraulic tester K1 by 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 shift indica-
tor 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 HD465-7E0, HD605-7E0
8. Testing transmission 2nd clutch and pilot 9. Testing transmission 3rd clutch and pilot
pressure pressure
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
tor shows "F4".
tor shows "F2".
k
k
In F4, a maximum travel speed of
ing area is safe.
ing area is safe.
condition.
condition.
HD465-7E0, HD605-7E0 9
10. Testing transmission 4th clutch 11. Testing transmission R clutch

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.
tor 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 HD465-7E0, HD605-7E0
Adjusting transmission speed sensor 1
a Adjust the 3 speed sensors installed to the 3. Secure lock nut (3) with sensor (1).
transmission according to the following proce- 2 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 or tooth end face 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)".
HD465-7E0, HD605-7E0 11
Testing and adjusting brake oil 4) Test the cut-out pressure at high idle.
q Read the ACC oil pressure (front or
pressure 1 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:
799-261-1204 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: 40 MPa {400 kg/cm²}).
1. Testing ACC accumlator charge oil pres-

sure
(Method using monitoring)
1) Set the machine monitor in service mode
and display the following 2 items simulta-
neously with the monitoring function.
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] Press 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 HD465-7E0, HD605-7E0
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 [40 MPa {400 kg/cm²}]. pressure gauge (C1) [40 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 20. ring to "Bleeding air from brake cir-
cuit" to see page 21.
3. Testing parking brake releasing pressure
1) Remove air bleeder (2) and install Oil
pressure gauge K1 [40 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 21.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
Nipple
792-610-1320 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-
Nipple
792-610-1350 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.
k
q Nitrogen gas cylinder (c) must be
Put on proper protection gear (goggles, connected even when you measure
leather gloves and protective clothes) so only the gas pressure.
that the leaking nitrogen gas will not touch q Close the valve of nitrogen gas cylin-
your skin or clothes and work on the wind- der (c) and handle (b).
ward side as long as possible.
k
q For connection of nitrogen gas cylin-
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 press the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is pressed 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).
HD465-7E0, HD605-7E0 15
4. Slowly rotate handle (a) of gas charge tool P1 5. If the gas pressure is too high or too low, adjust
clockwise and read the gauge. it referring to "Procedure for charging accumu-
a Since the indicated gas pressure varies lator with nitrogen gas".
with the atmospheric temperature, check it a Each time the pressure is measured, some
with the following table. nitrogen gas is discharged and the pres-
sure lowers. Add nitrogen gas by the loss.
Indicated gas pressure =
Standard gas pressure x ((273 + t)/
6. Remove gas charge tool P1 from accumulator
(273 + 20))
(1) and return the removed parts. See "Proce-
t = Gas temperature at time of charge (° dure for charging accumulator with nitrogen
C) gas".
Reference : t may be assumed to be ambi-
ent temperature. Procedure for charging accumulator with nitro-
: The unit of each value in the gen gas
formula is °C. a The disconnected from the machine can be
Accumulator charge gas pressure table charged with nitrogen gas according to the fol-
lowing procedure, too.
Gas pressure 1. Stop the engine and press the brake pedal
For rear repeatedly to lower the oil pressure in the
Atmospheric
temperature
For front service brake
Remarks
brake circuit to zero.
°C
service brake and parking a Generally, if the brake pedal is pressed 30
brake times, the reaction force to the brake
MPa kg/cm2 MPa kg/cm2 pedal is lost and the oil pressure is low-
15 10.52 107.1 6.09 61.9 ered to zero.
16 10.55 107.5 6.12 62.1
2. Remove valve guard (2) and cap (3) from
17 10.59 107.9 6.14 62.4 accumulator (1).
18 10.63 108.3 6.16 62.6
19 10.66 108.6 6.18 62.8
Standard gas
20 10.70 109.0 6.20 63.0
pressure
21 10.74 109.4 6.22 63.2
22 10.77 109.7 6.24 63.4
23 10.81 110.1 6.26 63.6
24 10.85 110.5 6.28 63.9
25 10.88 110.9 6.31 64.1
26 10.92 111.2 6.33 64.3
27 10.96 111.6 6.35 64.5
28 10.99 112.0 6.37 64.7
29 11.03 112.3 6.39 64.9
3. Connect gas charge tool P1 and nitrogen gas
30 11.07 112.7 6.41 65.2 cylinder (c) to valve (4) of accumulator (1)
31 11.10 113.1 6.43 65.4 according to the following procedure.
32 11.14 113.5 6.45 65.6 1) Turn handle (a) of gas charge tool P1 to
33 11.17 113.8 6.48 65.8 the left until it stops.
2) Turn handle (b) to the left to open.
34 11.21 114.2 6.50 66.0
3) Connect gas charge tool P1 to valve (4) of
35 11.25 114.6 6.52 66.2 accumulator (1).
36 11.28 115.0 6.54 66.4 4) Connect gas charge tool P1 and nitrogen
37 11.32 115.3 6.56 66.7 gas cylinder (c).
38 11.36 115.7 6.58 66.9 q There are 2 types of threads of nitro-
gen gas cylinders, W22-14 thread
39 11.39 116.1 6.60 67.1 (mail screw, type A) and W23-14
40 11.43 116.4 6.62 67.3 thread (female screw, type B). When
41 11.47 116.8 6.64 67.5 using a gas cylinder of W23-14 thread
(female screw, type B), connect the
42 11.50 117.2 6.67 67.7
hose by using the adapter. (The
43 11.54 117.6 6.69 67.9 adapter is attached to gas charge tool
44 11.58 117.9 6.71 68.2 P1.) [For Japan]
45 11.61 118.3 6.73 68.4
q Use nipple P2 to connect the hose,
depending on the specification of the
nitrogen gas cylinder. [For overseas]
16 HD465-7E0, HD605-7E0
8. During the work, close the valve of nitrogen

gas cylinder (c) and check the nitrogen gas
pressure in the accumulator.
a Since the indicated gas pressure varies
with the atmospheric temperature, correct
it with the following table.
Indicated gas pressure =
Standard gas pressure x ((273 + t)/
(273 + 20))
t = Gas temperature at time of charge (°
C)
Reference : t may be assumed to be ambi-
ent temperature.
: The unit of each value in the
formula is °C.
Accumulator charge gas pressure table
Gas pressure
For rear
Atmospheric
For front service brake
temperature Remarks
service brake and parking
°C
brake
MPa kg/cm2 MPa kg/cm2
15 10.52 107.1 6.09 61.9
16 10.55 107.5 6.12 62.1
17 10.59 107.9 6.14 62.4
18 10.63 108.3 6.16 62.6
19 10.66 108.6 6.18 62.8
4. Open nitrogen gas cylinder (c) slightly to dis- Standard gas
20 10.70 109.0 6.20 63.0
pressure
charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}. 21 10.74 109.4 6.22 63.2
22 10.77 109.7 6.24 63.4
5. After nitrogen gas starts flowing out of handle 23 10.81 110.1 6.26 63.6
(b), close handle (b). 24 10.85 110.5 6.28 63.9
25 10.88 110.9 6.31 64.1
6. Turn handle (a) slowly to the right to open 26 10.92 111.2 6.33 64.3
valve (4) of accumulator (1) gradually.
27 10.96 111.6 6.35 64.5
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged 28 10.99 112.0 6.37 64.7
and gas will leak. Accordingly, operate 29 11.03 112.3 6.39 64.9
handle (a) carefully. 30 11.07 112.7 6.41 65.2
31 11.10 113.1 6.43 65.4
7. Open the valve of nitrogen gas cylinder (c) fur- 32 11.14 113.5 6.45 65.6
ther to charge the accumulator with nitrogen 33 11.17 113.8 6.48 65.8
gas.
34 11.21 114.2 6.50 66.0
35 11.25 114.6 6.52 66.2
36 11.28 115.0 6.54 66.4
37 11.32 115.3 6.56 66.7
38 11.36 115.7 6.58 66.9
39 11.39 116.1 6.60 67.1
40 11.43 116.4 6.62 67.3
41 11.47 116.8 6.64 67.5
42 11.50 117.2 6.67 67.7
43 11.54 117.6 6.69 67.9
44 11.58 117.9 6.71 68.2
45 11.61 118.3 6.73 68.4
HD465-7E0, HD605-7E0 17
9. After the accumulator is charged to the stan- 13. In a week after charging the accumulator with
dard pressure, close the valve of nitrogen gas nitrogen gas, check that the nitrogen gas pres-
cylinder (c). sure has not lowered.
q If the accumulator is charged too much, a Check the functions in 5 minutes after
turn handle (b) to the left slowly with the stopping the engine. (If the engine is
valve of nitrogen gas cylinder (c) closed to stopped for more than 5 minutes, the
release the nitrogen gas gradually to brake circuit pressure lowers and the func-
adjust. tions cannot be checked accurately.)
1) Stop the machine on a level place and set
10. Remove gas charge tool P1 from valve (4) of the parking brake switch in the "PARK"
accumulator (1) according to the following pro- position.
cedure. 2) Start the engine and run it at medium
1) Turn handle (a) to the left to close the speed for 1 minute and then stop it.
valve of the accumulator. 3) Turn the starting switch to the ON position
2) Turn handle (b) to the left to open and dis- and press the brake pedal repeatedly.
charge nitrogen gas remaining in gas Count the number of presses until the
charge tool P1 and hoses. brake oil pressure caution lamp lights up.
3) Remove gas charge tool P1 from valve (4) q If number of presses is less than 5:
of the accumulator. Accumulator gas pressure may have
lowered.
11. Apply soap water to valve (4) of the accumula- q If number of presses is 5 or more:
tor to check that nitrogen gas is not leaking. Accumulator gas pressure is normal.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
18 HD465-7E0, HD605-7E0
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.
k
brake switch OFF.
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.
k If the torque converter is stalled
chine start moving during the performance
test, reduce the engine speed immediately,
while the gearshift indicator is indi-
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".
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
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".
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
while the gearshift indicator is indi-
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
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".
HD465-7E0, HD605-7E0 19

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.
20 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 21
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 gauge contacts
t h e m o u t h o f t h e h o l e , t h e pa d h a s
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.
22 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 23
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) (01017-51245),

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.
24 HD465-7E0, HD605-7E0
Testing and adjusting front

suspension cylinder 1
– 792-610-1000 Suspension tool assembly
– 792-610-1100 •Pump Ass'y
1 792-610-1130 ••Pump
2 792-610-1110 ••Hose
3 792-610-2200 ••Joint
– 792-610-1200 •Charging tool assembly
L 4 07020-21732 ••Fitting a With the truck empty, starting switch ON, park-
5 792-610-1140 ••Joint ing brake OFF, and hoist control lever at the
6 792-610-1250 ••Valve Ass'y FLOAT position, check that the cylinder of the
7 792-610-1260 ••Nipple
variable damper valve is in the soft mode.
a If the cylinder of the variable damper valve is
8 792-610-1270 ••Hose not in the soft mode when checking, operate
9 792-610-1280 ••Valve as follows to switch to the soft mode.
10 792-610-1400 ••Regulator 1] Use the retarder brake (Note 1) and drive
the machine several times repeatedly for-
"–" : Kit tool Nos.
ward and in reverse to set to the soft
k
mode.
Stop the machine on level ground, turn the
(*1) If the foot brake pedal is used, the auto-
parking brake switch PARKING, and put
matic suspension is automatically set to
chocks under the tires.
the medium mode, and the resistance of
the cylinder increases, so it takes time to
1. Testing length of cylinder adjust.
1) Check that the bottom of the cylinder
cover is within the range (e) marked by 2. Bleeding nitrogen gas
arrows for the cylinder level.
1) Set hydraulic jack [1] (500 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
intake valve (3), the valve core may
2) Before adjusting the oil level, check the be damaged. Accordingly, bleed
condition of the variable damper valve. through oil level valve (1).
(For only automatic suspension specifica- a Loosen only the oil level valve. Do
tion) not loosen the pressure sensor and
(S) posision: soft mode nipple.
(H) posision: hard mode a When the oil level valve is loosened,
(M) posision: medium mode if both of the oil and gas spout out,
close the valve a little to bleed the gas
slowly.
HD465-7E0, HD605-7E0 25
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 of oil level

a Release the nitrogen gas before adjusting
the oil level.
1) Remove feed vavle (3), and install joint
L5.
2) Install fitting L4 to joint L3, then connect
hose L2 and volume pump L1.
3) Loosen air bleeding valve (4), then oper-
ate volume pump L1 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 L1 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}
26 HD465-7E0, HD605-7E0
4. Filling suspension cylinder with gas

k Put on proper protection gear (goggles,
leather gloves and protective clothes) so
that the leaking nitrogen gas will not touch
your skin or clothes and work on the wind-
k When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate the work place forcibly and
observe the Oxygen Deficiency Prevention
Rules of the Labor Safety and Sanitation
Law.
1) Remove feed valve (3).
2) Set tool L as shown in the diagram.
a Before installing regulator L10, blow
the connector filter with nitrogen gas
at 1 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 (c)
(internal pressure of gas cylinder).
a The pressure indicated must be at
least 1 MPa {10 kg/cm²} higher than
the pressure inside the suspension
cylinder (max. pressure inside sus-
pension cylinder: 4.31 MPa {44 kg/
cm²}).
4) Turn handle (d) of regulator L10 slowly
counterclockwise, set the pressure read-
ing of gauge (e) to 1 MPa {10 kg/cm²}
above the internal pressure of the suspen-
sion cylinder, then operate valves L6 and
L9 to fill the suspension cylinder with nitro-
gen 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 (d) of regulator L10 clockwise to
stop the flow of nitrogen gas.
a Standard dimension (a): 249 – 10 mm
6) Turn handle (c) of L9 fully back counter-
clockwise, loosen air bleeding plug (f) of
valve L6, release the gas inside the hose,
then remove tool L.
a Be careful not lose the O-ring of the
feed valve.
HD465-7E0, HD605-7E0 27
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.
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
the packing and bushing). Under this con-
dition, 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,
check that the suspension is in the Note: 1. Check after replacement of oil or gas
soft mode. When the machine operates after the oil or
2) If the result of the check shows that the gas is replaced, gas is dissolved in the
installed length is too long, release nitro- new oil in the replaced cylinder until the oil
gen gas to adjust the length. is saturated. As a result, the gas volume
a Loosen the valve (1) slightly to is reduced and the installed length of the
release the nitrogen gas. When suspension may be reduced to below the
doing this, release only a small limit. Accordingly, measure the installed
amount of gas; do not make the cylin- length of the suspension again 48 hours
der move. after the oil or gas is replaced. If it is less
a If the nitrogen gas is bled so much than the specification value, adjust the
that the cylinder will move, the in- gas.
stalled length may be less than the
specified length. 2. Checking for changes in installed
a Do not press the tip of the valve core. length caused by variation in ambient
If the tip of the valve core is pressed, temperature.
the valve core may be damaged. Depending on the ambient temperature
3) After releasing nitrogen gas and adjusting when the machine is working, the gas in
the installed length, repeat Step 1) to the suspension may expand or contract,
check the installed length again. so the installed length will also change. In
4) Repeat the above Steps 1) – 3) to adjust territories where there are big differences
the cylinder to the specified length. in temperature throughout the year,
5) Finally, check that there is no leakage of inspect daily and adjust to keep the
gas from the valve core (6), valve (1), and installed length within the specified range.
piston rod gland.
a Use soapy water to check for leakage
of gas.
28 HD465-7E0, HD605-7E0
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
– 792-610-1000 Suspension tool assembly
– 792-610-1100 •Pump Ass'y
1 792-610-1130 ••Pump
2 792-610-1110 ••Hose
3 792-610-2200 ••Joint
– 792-610-1200 •Charging tool assembly
L 4 07020-21732 ••Fitting
5 792-610-1140 ••Joint
6 792-610-1250 ••Valve Ass'y
7 792-610-1260 ••Nipple
8 792-610-1270 ••Hose
2) Disconnect pressure sensor connector (2)
9 792-610-1280 ••Valve of valve (1), then loosen the valve 2 – 3
10 792-610-1400 ••Regulator turns.
"–" : Kit tool Nos. a When releasing the nitrogen gas,
there is danger that releasing the gas
k Stop the machine on level ground, turn the from the valve core of feed valve (3)
parking brake switch PARKING, and put will damage the valve core, so
chocks under the tires. remove the gas at the valve (1).
a When checking, stop the empty machine on a a When loosening the valve (1), loosen
flat place. only the valve itself. Do not loosen the
pressure sensor or nipple.
k When loosening the valve (1),
1. Testing length of cylinder
1) Remove dust cover. gradually loosen only valve (1) it-
2) Check that dimension (a) of the rear sus- self, and do not remove the valve
pension cylinder is within the specified until all the nitrogen gas has been
value. released from the slit.
k If the nitrogen gas has not all been
Specified value for dimension (a) :
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.
HD465-7E0, HD605-7E0 29
4. Filling suspension cylinder with gas

k Put on proper protection gear (goggles,
leather gloves and protective clothes) so
that the leaking nitrogen gas will not touch
your skin or clothes and work on the wind-
k When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate the work place forcibly 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 L10, blow
the filter in the connector with nitro-
1) Remove feed valve (3), and install joint
gen gas at 1 MPa {10 kg/cm²} or more
L5.
to blow out all dirt or dust. (Dirt or dust
2) Install fitting L4 to joint L3, then connect in the system causes failures.)
hose L2 and volume pump L1.
3) Open valve [2] of the gas cylinder [1], and
3) Loosen air bleeding valve (1), then oper- check the pressure reading of gauge (c)
ate volume pump L1 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 1 MPa {10kg/cm²} higher than
4) When no more bubbles come out with the the pressure inside the cylinder (max.
oil, tighten air bleeding valve (1). pressure inside cylinder: 2.74 MPa
5) After adding oil, remove the volume pump, {28 kg/cm²}).
then install feed valve (3). 4) Turn handle (d) of regulator L10 slowly
counterclockwise, set the pressure read-
ing of gauge (e) to 1 MPa {10kg/cm²}
above the internal pressure of the cylinder,
then operate valves L6 and L9 to fill the
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 (d) of regulator L10 clockwise to
stop the flow of nitrogen gas.
a Standard dimension (a) :
204 ± 10 mm
30 HD465-7E0, HD605-7E0
6) Turn handle (f) of L9 fully back counter- the packing and bushing). Under this con-
clockwise, loosen air bleeding plug (g) of dition, measure the installed length.
valve L6, 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
that the cylinder will move, the
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
HD465-7E0, HD605-7E0 31
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}
32 HD465-7E0, HD605-7E0
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 lon-
ger 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
HD465-7E0, HD605-7E0 33
Testing and adjusting hydraulic

pressure in steering, hoist circuit1
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 (40 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).
34 HD465-7E0, HD605-7E0
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 measurement plug
adjust the pressure. (1) and install tool K1 (40 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 (40
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 testing plug (7) (when
turning the steering to the left) or pressure
testing plug (8) (when turning the steering
to the right), and install tool K1 (40 MPa
{400 kg/cm²}).
the hydraulic pressure in the steering cir-
cuit.
HD465-7E0, HD605-7E0 35
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 (40
MPa {400 kg/cm²}).
the hydraulic pressure in the hoist circuit.
36 HD465-7E0, HD605-7E0
Testing and adjusting oil pressure 2. Testing dump EPC valve output pressure
in dump EPC circuit 1 1) Disconnect EPC hose (3) or (4) to be mea-
sured.
a Testing instrument (3): Dump raise side (Port PB)
(4): Dump lower side (Port PA)
1
790-261-1204 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-
1. Testing dump EPC valve main pressure nect the hose.
1) Remove oil pressure testing plug (2) (M14 3) Install nipple [1] and hose [2] and connect
× 1.5) from dump EPC valve (1) inside oil pressure gauge K1 [6 MPa {60 kg/
the hydraulic tank (inside the machine). cm²}].
4) Start the engine, set the dump lever to the
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 [6 MPa {60 kg/
cm²}].
3) Start the engine and test the oil pressure
when the dump lever is in neutral.
HD465-7E0, HD605-7E0 37
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.
38 HD465-7E0, HD605-7E0
Procedure for raising dump body 3. Stop the engine and remove tool M and install
plug (1).
in emergency 1 3 Tightening torque of plug:
a Testing instrument 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
Symbol Part No. Part name a For the body lowering procedure, see "Proce-
M 792T-192-1110 Plug dure for lowering dump body in emergency".
a If the dump body cannot be raised because of

a failure in the controller or electric system,
raise it to dump the load according to the fol-
lowing procedure.
1. Stop the engine and remove the hydraulic tank

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

a If tool M is tightened in fully, the spool is
moved to the rising stroke end.
a Plug (2) is for lowering the dump body.
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.
HD465-7E0, HD605-7E0 39
Procedure for lowering dump Serial number

HD465-7E0: 10694 and up
body in emergency 1 HD605-7E0: 10694 and up
1. Remove hydraulic tank cap (3) to release the
Symbol Part No. Part name residual pressure in the hoist circuit.
M 792T-192-1110 Plug
a If the dump body lowering function does not

work because of a trouble of the controller or
electrical system, lower the dump body accord-
Serial number
HD465-7E0: 10001 – 10037, 10101 – 10693
HD605-7E0: 8001 – 8032, 10101 – 10693
1. Remove plug (2) and tighten tool M slowly.

k Be sure to perform the work from the
ground and do not enter under the 2. Tighten locknut (5) of manual lowering valve
bump body. (4).
a The dump body lowers by itself. Lower it
at safe speed while adjusting the tighten- 3. Rotate grip (6) of valve (4) counterclockwise
ing depth of tool M. slowly to drain the oil from the hoist cylinder.
a Plug (1) is for raising the dump body. k Be sure to perform the work from the
a For the body raising procedure, see "Pro- ground and do not enter under the
cedure for raising dump body in emer- bump body.
gency". a The dump body lowers by itself. Lower it
at safe speed while adjusting the tighten-
2. After the dump body lowers completely, ing quantity of grip (6).
remove tool M and install plug (2).
3 Tightening torque of plug: 4. After the dump body lowers completely, rotate
44.1 – 53.9 Nm {4.5 – 5.5 kgm} grip (6) clockwise to close valve 4 and tighten
locknut (5).
40 HD465-7E0, HD605-7E0
a For the body raising procedure, see "Proce-

dure for raising dump body in emergency".
HD465-7E0, HD605-7E0 41
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.
42 HD465-7E0, HD605-7E0
Handling of 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
inse rted or con nected to th e conne ctor repaired or replaced.
between the engine controller and the engine q If the transmission controller is 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)".
HD465-7E0, HD605-7E0 43
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.
44 HD465-7E0, HD605-7E0
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 — ccurrence 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: F1, 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 can travel normally (Note 1). lever is set to N position
once.
If display becomes normal, machine
DAQ2KK Occurrence condition1 Escape procedure4 can travel normally (Note 1).
DAQ9KQ Occurrence condition4 Escape procedure6 —

DAQRKR Occurrence condition2 Escape procedure5
can travel normally (Note 1).
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
HD465-7E0, HD605-7E0 45
Failure Condition when Starting gear speed set with lever

code trouble occurred Escape method position after escape operation Remarks
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
DF1KA 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
46 HD465-7E0, HD605-7E0
Escape procedure 1: Escape procedure 7:

1. Stop traveling and return the gearshift lever to Check the fuse. If it is normal, replace the gearshift
the "N" position. lever.
2. Operate the gearshift lever again and move q Fuse: BT3-No. 14 (10 A)
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. Disconnect (pull out) emergency escape con-
nectors A1 (female) and A1 (male) and then
connect (insert) them again to set the machine
in the emergency escape mode.
a Connectors A1 (male and female) are
installed to near the fuse box.
a Disonnect and connect 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)
q Fuse: BT2-No. 18 (10 A)
Escape procedure 6:
Check the model selection setting. If it is normal,
see adjustment of transmission controller.
HD465-7E0, HD605-7E0 47

© 2009 KOMATSU
All Rights Reserved
48 HD465-7E0, HD605-7E0
SEN01652-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Setting and adjusting of devices ..................................................................................................................... 2
Special functions of machine monitor (EMMS) ............................................................................................. 14
HD465-7E0, HD605-7E0 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 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 (At 06310).
*3-2: For the setting and adjusting procedure, see Service News (At 06310).
1
2 HD465-7E0, HD605-7E0
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 MACHINE FAULT
Mechanical system failure history
display function
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases REAL-TIME
Real-time monitoring function
MONITOR
q [U]: Number at the cursor is deter-
CYLINDER
mined CUT-OUT
Reduced cylinder 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)
HD465-7E0, HD605-7E0 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 In the " " part, the model presently
* q [<] switch: To return to previous model
set is displayed. 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
HD465 HD465-7E0
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 HD465-7E0 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 HD465-7E0, HD605-7E0
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".
HD465-7E0, HD605-7E0 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 AURTO 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 correction quantity for tire size.
HD465-7E0 : 0 %
HD605-7E0 : 0 %
Tire size correc-
TIER SIZE 12 0% • If speedometer reading is not correct, adjust it with
tion
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
SPEED (UNIT) 15 MPH • When km/h is used: km/h
(MPH / km/h)
a This item is not displayed for 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 HD465-7E0, HD605-7E0
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 correction
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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. TOR) 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 HD465-7E0, HD605-7E0
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
the section "Spe cial function 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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Operator mode io Service mode

1 Service meter, odometer display function (default) (*1) 10 Electric system fault history display function
2 Dumping 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 Reduced cylinder 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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 17
t Operator mode (Outline) [3] Integrated reverse odometer display func-

tion
[1] Service meter and integrated odometer dis- Machine monitor displays the integrated reverse
play function odometer by operating the switch.
When turning the starting switch ON, the speed 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] Dumping counter display function played automatically)
(When option is selected) When the replacement interval for the various
Display the dumping counter by operating the filters or oils approaches, the machine monitor
machine monitor switch. automatically displays the information to
a Dumping counter is displayed only when the remind an operator of maintenance.
option selection is set to be effective in the ser-
vice mode.
18 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 pres-
ing on the extent of the abnormality in order to ent 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 HD465-7E0, HD605-7E0
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).
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

Failure contents
2C4MNX Clogging of retarder cooling oil filter BK E01 Electrical 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@BFZK) Lowering of fuel level MON — —
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@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 temperature sensor ENG E01 Electrical system
CA222 Abnormally low level of ambient temperature sensor ENG E01 Electrical system
CA227 Abnormally high level of sensor power supply 2 ENG E03 Electrical system
CA234 Overspeed of engine ENG E02 Mechanical system
CA238 Abnormality in Ne speed sensor power supply ENG E03 Electrical system
HD465-7E0, HD605-7E0 23

Failure contents
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
CA1228 Abnormality 1 in EGR valve servo ENG E03 Electrical system
CA1625 Abnormality 2 in EGR valve servo ENG E03 Electrical system
CA1626 Short circuit in bypass valve solenoid drive system ENG E03 Electrical system
CA1627 Disconnection in bypass valve solenoid drive system ENG E03 Electrical system
CA1628 Abnormality 1 in bypass valve servo ENG E03 Electrical system
CA1629 Abnormality 2 in bypass valve servo ENG E03 Electrical system
CA1631 Abnormally high level of bypass valve lift sensor ENG E03 Electrical system
CA1632 Abnormally low level of bypass valve lift 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
CA2271 Abnormally high level of EGR valve lift sensor ENG E03 Electrical system
24 HD465-7E0, HD605-7E0

Failure contents
CA2272 Abnormally low level of EGR valve lift sensor ENG E03 Electrical system
CA2351 Short circuit in EGR valve solenoid drive ENG E03 Electrical system
CA2352 Disconnection in EGR valve solenoid drive 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
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
(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
VHMS
DBB0KK VHMS controller (Low source voltage (input)) — Electrical system
(indication: PLM)
VHMS
DBB0KQ VHMS controller (Disagreement of model selection signals) — Electrical system
(indication: PLM)
VHMS controller battery power supply VHMS
DBB3KK — Electrical system
(Low source voltage (input)) (indication: PLM)
VHMS controller 5V power supply output VHMS
DBB5KP — Electrical system
(Low output voltage) (indication: PLM)
VHMS controller CAN communication (Defective communi- VHMS
DBBQKR — Electrical system
cation (Abnormality in target component system)) (indication: PLM)
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
HD465-7E0, HD605-7E0 25

Failure contents
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
Atmospheric temperature sensor VHMS
DGE5KX — Electrical system
(Out of input signal range) (indication: PLM)
Transmission oil temperature sensor input signal out of
DGF1KX TM E03 Electrical system
range
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
VHMS
DGT4KA Exhaust gas temperature sensor (F) (Disconnection) — Electrical system
(indication: PLM)
VHMS
DGT4KB Exhaust gas temperature sensor (F) (Short circuit) — Electrical system
(indication: PLM)
VHMS
DGT5KA Exhaust gas temperature sensor (R) (Disconnection) — Electrical system
(indication: PLM)
VHMS
DGT5KB Exhaust gas temperature sensor (R) (Short circuit) — Electrical system
(indication: PLM)
VHMS
DHE5KB Blow-by pressure sensor (Short circuit) — Electrical system
(indication: PLM)
Blow-by pressure sensor VHMS
DHE5KY — Electrical system
(Short circuit with power supply line) (indication: PLM)
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)
26 HD465-7E0, HD605-7E0

Failure contents
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 Clinometer sensor signal out of range TM E01 Electrical system
VHMS
DKH1KX Abnormality in clinometer sensor 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
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
HD465-7E0, HD605-7E0 27

Failure contents
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)
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)
28 HD465-7E0, HD605-7E0

Failure contents
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
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
HD465-7E0, HD605-7E0 29

Failure contents
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
VHMS
F@BBZL Blow-by pressure (High error) — Electrical system
(indication: PLM)
VHMS
F@BYNR Exhaust gas temperature (F) (Abnormal heat) — Electrical system
(indication: PLM)
VHMS
F@BYNS Exhaust gas temperature (F) (Overheat) — Electrical system
(indication: PLM)
VHMS
F@BZNR Exhaust gas temperature (R) (Abnormal heat) — Electrical system
(indication: PLM)
VHMS
F@BZNS Exhaust gas temperature (R) (Overheat) — Electrical system
(indication: PLM)
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 HD465-7E0, HD605-7E0
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 a Displayed service menu:
operation for longer than 60 seconds, it No. Display Function
automatically returns to the operator mode
screen. Electrical system failure history
1 ELECTRIC FAULT
display function
Mechanical system failure
2 MACHINE FAULT
history display function
REAL-TIME
3 Real-time monitoring function
MONITOR
CYLINDER Reduced cylinder mode func-
4
CUT-OUT tion
5 NO INJECTION No injection cranking function
6 TUNING Adjusting function
HD465-7E0, HD605-7E0 31
MAINTENANCE Filter and oil replacement time [10] Electrical system failure history display
7 function (ELECTRIC FAULT)
MONITOR setting function
The machine monitor retains the data for problems
Operation information display
8 OPERATION INFO that occurred in the electrical system in the past as
function
failure history. They can be displayed as follows.
FIX POWER
9 Engine mode fixing function 1. Selection of the service menu
MODE
Select electrical system failure history display
10 SNAPSHOT Manual snap shot function function (ELECTRIC FAULT) in the service
PLM (Payload meter) setting menu selection screen.
11 PLM
function a The total number of failure history data
OPTIONAL items recorded in memory is displayed in
12 Option selection function the [* *] portion.
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.
a If you return to the operator mode
screen by mistake, repeat the proce-
dure from step 1 above (however
there is no need to input the ID again).
q When completing all operations:
Turn the starting switch OFF.
32 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

switch and display the failure history data
recorded in memory.
34 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 35

© 2009 KOMATSU
All Rights Reserved
36 HD465-7E0, HD605-7E0
SEN01653-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
HD465-7E0, HD605-7E0 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 is installed)
Select real time monitoring function (REAL- ABS controller
6 ABS
TIME MONITOR) in the service menu selec- (if equipped is installed)
tion screen. 2 items simultaneous monitor-
7 2 ITEMS
ing
a Display monitoring system and func-

tion 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]: Conduct 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 HD465-7E0, HD605-7E0
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 and display
real time. the monitoring code input screen.
monitoring
4) To hold or cancel monitoring data:

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. 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".
HD465-7E0, HD605-7E0 3
3) In the monitoring code input screen, oper- 6. Display data for 2 items simultaneous monitor-
ate each of the switches [>], [<], [U] and ing
[t], and directly input 2-digit monitoring On the 2 item simultaneous monitoring display
codes. screen, the following data are displayed.
q [ > ]: Number at the cursor increases. A : Monitoring code 1
q [ < ]: Number at the cursor decreases 1 : Monitoring data 1 (including unit)
q [U]: Number at the cursor is deter- B : Monitoring code 2
mined 2 : Monitoring data 2 (including unit)
q [ t]: Cursor moves to the left end / To a For details, see "Monitoring code table".
return to the monitoring system
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:

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 HD465-7E0, HD605-7E0
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/symbols)
********
2 Version No. of application VERSION (APP) 20221 —
(8 digits/symbols)
********
3 Version No. of data VERSION (DATA) 20222 —
(8 digits/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
HD465-7E0, HD605-7E0 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 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: 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 HD465-7E0, HD605-7E0
Transmission [Transmission controller system]
Monitor-
ing code
********
1 Part No. of software VERSION 20201 —
(8 digits/symbols)
********
(8 digits/symbols)
********
(8 digits/symbols)
0 – 32767
4 Transmission input shaft speed T/M SPEED:IN 31200 rpm
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
0 – 1000
22 Solenoid output (high) ECMV H DIR 31600 mA
HD465-7E0, HD605-7E0 7
Monitor-
ing code
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 Roll angle sensor ANGLE SENSOR 32900 ° [degree]
0.00 – 5.00
32 Roll 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
0101010 Learning flag
44 Trigger initial learning flag TRIG HL1234R 38920 (Data is displayed under of clutch
HL1234R) 0:OFF/1:ON
8 HD465-7E0, HD605-7E0
Monitor-
ing code
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Engine [Engine controller system]
Monitor-
ing code
1 Serial No. of hardware (left bank) ECM S/N 20400 0 – 49999999 —
0.0 – 480.0
2 Battery voltage (left bank) 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
-99.9 – 999.9
22 EGR valve differential pressure EGR DIF PRESS 17900 kPa
EGR valve differential pressure 0.00 – 5.00
23 EGR DIF PRESS 17901 V
sensor voltage ---- [Other than above]
-99.9 – 999.9
24 EGR valve inlet pressure EGR IN PRESS-A 18000 kPa
HD465-7E0, HD605-7E0 11
Engine [Engine controller system]
Monitor-
ing code
EGR valve inlet pressure sensor 0.00 – 5.00
25 EGR IN PRESS-A 18002 V
0.00 – 99.99
26 EGR valve position EGR VALVE POS 18100 mm
EGR valve position sensor volt- 0.00 – 5.00
27 EGR VALVE POS 18101 V
age ---- [Other than above]
-24000 – 24000
28 Engine output torque OUTPUT TORQUE 18700 Nm
0 – 100
29 Converted torque TORQUE RATIO 36700 %
0 – 100
30 Final accelerator position FINAL THROTTLE 31706 %
0.0 – 999.9
31 Momentary fuel consumption FUEL RATE 37300 L/h
Final injection rate command 0 – 1000
32 INJECT COMMAND 18600 mg
(by weight) ---- [Other than above]
-180.0 – 180.0
33 Final injection timing command INJECT TIMING 36300 CA
0 – 100
34 Accelerator pedal position THROTTLE POS 31701 %
0.00 – 5.00
35 Accelerator pedal sensor voltage THROTTLE POS 31707 V
0.00 – 99.99
36 Bypass valve position BPS VALVE POS 18200 mm
Bypass valve position sensor 0.00 – 5.00
37 BPS VALVE POS 18202 V
38 Idlie validation signal IVS 1 18300 ON or OFF —
39 Idlie validation signal IVS 2 18301 ON or OFF —
-40 – 210
40 Controller inside temperture ECM IN TEMP 18900 °C
Final common rail pressure com- 0 – 400
41 PRESS COMMAND 36200 MPa
mand ---- [Other than above]
PCV valve closing timing (based -180 – 180
42 PCV TIMING 17201 CA
on BTDC) ---- [Other than above]
43 Engine mode selection POWER MODE 17500 0–4 —
Transmitted value is dis-

44 Selected model (left 8 digits) MACHINE ID (H) 00400 —
played (Left 8 of 16 letters)
45 Selected model (right 8 digits) MACHINE ID (L) 00401 —
played (Left 8 of 16 letters)
46 Build version No. BUILD VER 20216 —
played (8 letters)
47 Calibration data version No. CAL VER 20217 —
played (8 letters)
a "CA" in the unit column is an abbreviation for the Crankshaft Angle.
12 HD465-7E0, HD605-7E0
Brake [Retarder controller system]
Monitor-
ing code
********
1 Version of software VERSION 20214 —
(8 digits/symbols)
********
(8 digits/symbols)
********
(8 digits/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 (Unuse) —
ture (front) [* Unuse]
Retarder cooling oil tempera-
9 BRAKE OIL T F 30204 (Unuse) —
ture (front) [* Unuse]
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]
0 – 1000
12 Brake output (front wheel) BK OUTP DIR F 33700 mA
0 – 1000
13 Brake output (rear wheel) BK OUTP DIR R 33806 mA
0.00 – 5.00
14 Retarder lever 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
0.0 – 10.00
24 Seating control time (low) S CNT TIME L 45403 second
HD465-7E0, HD605-7E0 13
Brake [Retarder controller system]
Monitor-
ing code
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 HD465-7E0, HD605-7E0
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 level switch
[30] : Steering hoist filter switch
[31] : Battery electrolyte level switch

[32] : Transmission/Brake oil level switch
HD465-7E0, HD605-7E0 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 Clinometer (pitch angle) INCLINOMETER 32901 (*) ° (degree)
0.00 – 5.10
10 Clinometer (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 HD465-7E0, HD605-7E0
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 in VHMS is set.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
ABS [ABS controller system] (If equipped)
Monitor-
ing code
1 Part No. of software VERSION 20210 ******** (8 digits/symbols) —
2 Version No. of application VERSION (APP) 20233 ******** (8 digits/symbols) —
3 Version No. of data VERSION (DATA) 20234 ******** (8 digits/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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 21
[13] Reduced cylinder 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 each of the switches [>], [<],
the machine monitor has a reduced cylinder mode [U] and [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 of 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.

[U] switch and display the reduced cylin-
der mode implementation screen.
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 implementation
During this time, the cylinder No. flashes.
screen, the cursor of cylinder selec-
After completion of the communication,
tion is always displayed under the
the segment under the cylinder No.
No.1 cylinder.
becomes white to show that the cylinder
cut-out has been canceled.
22 HD465-7E0, HD605-7E0
[14] No injection cranking function 3. Setting is denied during engine running

(NO INJECTION) During engine running, if the setting of none
The machine monitor has the function of none inj ec tion cr ank in g i s a ttemp ted, " STOP
injection cranking, which carries out cranking after ENGINE" is displayed in the lower line, and
long-term storage, stopping fuel injection of all the setting is rejected.
cylinders without starting the engine. a None injection cranking function cannot
a The function of none injection cranking must be used during engine running.
be operated under the condition that the
engine is stopped.
1. Selection of the service menu

In the service menu selection screen, select
none injection cranking function (NO INJEC-
TION).
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-
tion screen.
2. Establishment of no injection cranking
switch to display none injection cranking exe-
cution screen.
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.
HD465-7E0, HD605-7E0 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 below procedure.
initial learning and implement 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 by
services.
a For details concerning the operation method of
real time monitoring function, refer to "[11] real
time monitoring function".
If power train related operation such as the follow-
ing is carried out, execute the adjustment opera-
tion.
q If transmission is overhauled or changed
q If 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 right table for failure code)
q If the transmission oil temperature sensor is
troubled and repaired (refer to the below table
for failure code)
q If the transmission oil filter is clogged and
repaired (refer to the below table for failure
code)
1. Preparing operations for "Adjusting trans-
Failure code Device name mission ECMV electric 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 R 1) Select real time monitoring function
DLF3KA (REAL-TIME MONITOR) in the service
speed sensor
menu selection screen.
Transmission valve oil tempera-
DGF1KX
ture sensor
15BONX Transmission oil filter
24 HD465-7E0, HD605-7E0
2) With the service menu selected, press the 7) Depress the brake pedal, and set the gear
[U] switch to display the monitoring sys- shift lever to D position.
tem and function selection screen. a Confirm that the shift indicator dis-
q [U]: Runs service menu plays "F2".
3) In the monitoring system and function 8) Stall the torque converter and 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 data for previous keep it for 3 minutes, and confirm that the
monitoring 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 electric cur-

rent
a Adjustment is carried out four times auto-
matically against the Hi, Lo, R, 1st, 2nd
and 3rd, 4th valves respectively.
1) Refer to "1. Preparation of operations for
adjusting transmission ECMV electric cur-
rent", and select the monitoring code of
transmission oil temperature.
4) With the transmission system selected, q Monitoring code:
press the [U] switch and display the mon- 32500 (T/M OIL TEMP)
itoring display and item selection screen. a At this time, do not start the engine.
monitoring
q The program version No. is displayed
on ********.
5) In the monitoring display and item selec-
tion screen, press [>] switch or [<] switch
and select monitoring code of transmis-
sion oil temperature.
q [>]: Goes on to the next monitoring
item
q [<]: Goes 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 (Release)
6) Confirm that the parking brake switch is

PARKING, and start the engine.
HD465-7E0, HD605-7E0 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]: Runs service menu a The lower line display changes from
5) On the adjustment menu selection screen, "IP" to "IP ***".
press [>] switch or [<] switch, and select
ECMV current adjustment item (02: ECMV
TUNING).
q [>]: To proceed to the next adjust-
ment menu
q [<]: To go back to the previous adjust-
ment menu
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 below table 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 menu selected, press 2 HIGH IP H-1 IP H-2 IP H-3 IP H-4
[U] switch and 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 switch to the next compensa-
tion screen.
q Compensation menu: AUTO
26 HD465-7E0, HD605-7E0
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 electric current". (If adjust-
ments are made at temperatures other than
specified temperature, time lag or gear
shift 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 ab- roundings for safety.
normal result 1) Select (TUNING) in the service menu
Code Condition 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:
Adjustment is done without error.
q If "NG1" is displayed (out of compen-
sation condition):
Adjust the transmission oil tempera-
ture exactly, and confirm the machine
setting conditions again, then c a r r y
out the adjustment from procedure 1).
q If "NG2" (no fill) is displayed: 2) While the service menu is selected, hold
Carry out troubleshooting of failure down the [U] switch for a minimum of 5
code [15S*MA][DDT*KA], and if the seconds to display the adjustment menu
condition is confirmed to be normal, selection screen.
then start again from procedure 1) q [U]: To conduct the service menu.
(The symbol with * mark varies by 3) With the adjustment menu selection
objective clutches). screen, confirm that the transmission trig-
q If "NG3" is displayed (compensation ger adjustment item (01: TM TRIGGER) is
value over): displayed.
Carry out troubleshooting of failure
code [15S*L1], and if the condition is
confirmed to be normal, then start i t
again from procedure 1) (The symbol
with * mark varies by objective clutch-
es).
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.
HD465-7E0, HD605-7E0 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 former 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
[U] switch to display the monitoring sys-
tem and function selection screen.
q [U]: To conduct 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 data for previous
monitoring system and function
6) With the initialization operation screen dis-

played, operate each of the switches [<],
[>] and [t] to execute initialization.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor).
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 HD465-7E0, HD605-7E0
10) With 2 items simultaneous monitoring se-

lected, press the [U] switch and display
the monitoring code input screen.
q [U]: Execute monitoring system and
function.
11) In the monitoring code input screen, oper-
ate each of the switches [>], [<], [U] and
[t], and directly input 2-digit monitoring
codes.
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases
mined
q [ t]: Cursor moves to the left end / To
15) Set the gearshift lever in the 6 position
return to the monitoring system
and press the accelerator pedal fully to
and function selection screen.
run the truck and shift up the gear to F6.
q Monitoring code: 32500 and 38920
a Shifting up: F1 o F2 o F3 o F4 o
a Indicate the transmission oil tempera-
F5 o F6
ture in the upper row (32500) and
16) After the gear is shifted up to F6, release
study condition of clutch trigger in the
the accelerator pedal and shift down the
lower row (38920) (0: not learned yet,
gear to F1 by coasting run.
1: already learned).
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.
a The * marked clutch display can be
12) Set AISS LOW switch to LOW. either "0" or "1".
13) Start the engine, keep the gear shift lever
at N position for 10 seconds 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.
either "0" or "1".
HD465-7E0, HD605-7E0 29
18) Set the gearshift lever in the 4 position 23) Check that the trigger learning of the Hi
and press 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.
either "0" or "1".
24) Set the gearshift lever in position 4 and

press the accelerator pedal fully to 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, press 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-
ger learning of the low clutch and 3rd
21) Set the gearshift lever in the 3 position clutch is displayed on the monitor.
and press the accelerator pedal fully to a If "1" is displayed, go to the next step.
run the truck and shift up the gear to F3. a If "0" is displayed, repeat steps 24) –
a Shifting up: F1 o F2 o F3 26) until "1" is displayed.
22) After running the machine at F3 for 10 a If "1" is not displayed after repeating
seconds, release the accelerator pedal the steps 4 times, the ECMV may be
and shift down the gear to F1 by coasting defective. In this case, replace the
run. ECMV.
a Shifting down: F3 o F2 o F1 a The * marked clutch display can be
a Do not apply the brake during coast- either "0" or "1".
ing run.
30 HD465-7E0, HD605-7E0
27) Set the gearshift lever in the 2 position

and press the accelerator pedal fully to
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
and shift down the gear to F1 by coasting
run.
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.
30) In the monitiring display, confirm finally the

trigger learning display of lower line.
a If displayed as drawing, the initial
learning has completed normally.
31) Press [t] switch sereral times and com-

plete service menu.
q [t]: To return to the previous screen.
HD465-7E0, HD605-7E0 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 convertery/
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 – 14 are the maintenance items
[U] switch to display the maintenance where the setting is changed by item,
item and function selection screen. and No.15 – 16 are the functions
q [U]: Conduct the service menu. which allows to change the setting of
all items simultaneously.
a Display the item and function 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 HD465-7E0, HD605-7E0
3. Display contents of the maintenance item

(Items No.1 – 14)
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 items
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 each
of 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 – 14)
1) With the item selected on the mainte-
nance item and the function selection
screen to change the interval time (ex: P
FUEL FILT), press the [U] switch to dis-
play the interval change screen.
q [U]: Implement the function to
change maintenance item.
a The currently 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 – 14).
the screen switches to the setting 1) With the item selected on the mainte-
screen for activating or deactivating nance item and function selection screen
the maintenance item. (ex: FUEL P FILT) to change the activation
2) On the interval change screen, operate or deactivation of the function, press the
each of the switches [>], [<], [U] and [t] [U]switch to display the interval input
to input the interval time. screen.
q [ > ]: Number at the cursor increases. q [U]: Implement 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.
HD465-7E0, HD605-7E0 33
2) After displaying the screen to input inter- a If the timer which has been OFF is
vals, press the [>] switch or the [<] switch turned ON, the interval is set to the
to display the activation or deactivation value before it was turned OFF and
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 each of the switches [U] the [U] switch to display the all item
and [t]. default value setting screen.
q [U]: Switch to the change confirma- q [U]: Implement the function to set the
tion screen default values of all the items.
q [t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
2) Display the all item default value setting

screen and operate each [<], [>] and [t]
switches.
4) When the change confirmation screen is q [t]: Execute YES or NO
displayed, operate each [<], [>] and [t]
switches.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
a If the intervals for all the items are

changed in an item, all the items are
set to their respective 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 HD465-7E0, HD605-7E0
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. setting by the maintenance item and
the interval is set to the previous time
7. Setting the function activation or deactivation before the interval has been deacti-
for all the items (function No.16) vated.
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.
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 (OFF).
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 by the maintenance item.
HD465-7E0, HD605-7E0 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 0500
2 Engine oil 01 ENG OIL 0500
3 Engine oil filter 02 ENG FILT 0500
4 Transmission oil filter 13 TM FILT 1000
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 validity or invalidity for all items (None) ALL ITEMS —
setting function
36 HD465-7E0, HD605-7E0
[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.
HD465-7E0, HD605-7E0 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: Loading the number of time from the
q [>]: Switch the displayed screen
last reset point. [times]
q [<]: Change 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 and exe- q [t ]: To return to the service menu
cute 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 HD465-7E0, HD605-7E0
3) After displaying the compensation value

input screen, operate each of the switches
[>], [<], [U] and [t] to input the compen-
sation value directly.
q [ > ]: To switch the cursor symbol (+/-)
/ Number increases.
q [ < ]: To switch the cursor symbol (+/-)
/ Number decreases.
q [U]: Sign/number at the cursor is
determined.
q [ t]: Return to the fuel 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: Select setting screen
stall speed to check the engine performance. q [ < ] switch: Select setting screen
q Engine high idle speed q [t] switch: Engine mode fixing function
q Torque converter stall speed 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" about
mode and spec.
2. Selection of service menu

While the service menu selection screen is dis-
played, select the engine mode fixing function
(FIX POWER MODE).
HD465-7E0, HD605-7E0 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 observe the machine two or more [*] signs are displayed, the
operating 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 specified taking place stops the snapshot.
machine operating procedure is stipulated.
q When using the data being stored with the
manual snapshot function, a PC must be con-
nected. For the connecting as well as operat-
ing 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 SNAPSHOT screen from the menu
screen of Service mode.
4. Refer to the Pm clinic implementation proce-

dure for 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

2. Pressing [U] switch to turn on the ready start of the snapshot, following screen appears
(READY) screen. and then the initial screen is restored in 5 sec-
a The lower column displays 15 pieces of [–] onds later.
sign. (End of snapshot)
40 HD465-7E0, HD605-7E0
[20] PLM setting function (PLM)

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

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

(OPTIONAL SELECTION)
Machine monitor can set and adjust various
optional devices which have been installed or
removed.
a The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
[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 The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
HD465-7E0, HD605-7E0 41

© 2009 KOMATSU
All Rights Reserved
42 HD465-7E0, HD605-7E0
SEN01654-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Request for opening ORBCOMM terminal...................................................................................................... 2
VHMS controller initial setting procedure........................................................................................................ 4
Using method of KOMTRAX functions of ORBCOMM terminal.................................................................... 24
Precautions for replacing VHMS controller ................................................................................................... 27
Pm Clinic check sheet................................................................................................................................... 33
Initial setting of payload meter ...................................................................................................................... 37
Setting of payload meter built in VHMS ........................................................................................................ 38
Setting of card-type payload meter (PLM- ) after installation or replacement............................................. 46
HD465-7E0, HD605-7E0 1
Request for opening ORBCOMM

terminal 1
a If the machine is equipped with ORBCOMM, fill

in the "Request for opening VHMS ORB-
COMM terminal" and send it by fax or mail to
"KOMATSU KOMTRAX SUPPORT CENTER"
before initializing the VHMS controller.
a Initialize the VHMS controller after the opening
notification is received from "KOMATSU KOM-
TRAX SUPPORT CENTER".
a If the ORBCOMM antenna is installed and the
starting switch is turned to the ON position
before the opening notification is received, the
ORBCOMM terminal transmits radio waves
and ORBCOMM CO. LTD. sends out the stop
signal automatically. In this case, complicated
procedures and some time are required to
open the ORBCOMM terminal service again.
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3
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 ORBCOMM terminal in-
Note type PC formation.
N
Commercially (Windows 98/2000/Me/XP/ No. Information to be confirmed
3
available VISTA(*) and terminal
"RS232C" is with it) 1 Model name
* : VHMS setting tool Ver.3.06.00.03 or later, 2 Machine serial No.

VHMS analysis tool Ver.3.05.00.00 or later. 3 Current service meter hour
4 Engine serial No.
a Initial setting of VHMS controller shall be done 5 Transmission serial No.
according to the following procedure. This
operation is needed prior to a full-scale opera- 6 VHMS controller serial No.
tion of a machine being delivered and assem- ORBCOMM terminal serial No.
7
bled in the field, or prior to resumption of its [Only for machines equipped with ORBCOMM]
operation after a long time of storage.
a Machine data collected with VHMS controller 2. Connecting a PC
are stored and managed on WebCARE data- a This work is done inside the cab.
base. In order to endure smooth data process- 1) Make sure the starting switch is at OFF
ing on WebCARE , consistency must be position.
provided among the settings done on VHMS k Before connecting or disconnect-
controller. Inconsistencies in the settings ing a PC, be sure to turn off the
obstruct loading of data to WebCARE, ham- starting switch.
pering appropriate use of VHMS data. The ini- 2) Using harness N2, connect the PC N3 and
tial setting, therefore, is a must. download connector DPC7.
a For the method of installing the VHMS Initial- a Then connect the PC to RS232C ter-
ization Program to the personal computer, minal.
refer to the Operation and Maintenance Man-
ual contained in the package of diskette N1.
a Since the service menu of the machine monitor
will be used in the following procedure, read
" 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)" and understand the operating proce-
dure in advance.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM installation specification, imple-
ment the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOMM
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.
a During the initialization work, confirm each
work according to the "VHMS Initialization
Work Checklist".
4 HD465-7E0, HD605-7E0
a Download connector DPC7 is installed

to box (1) in 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 ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
terminal 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, the
ORBCOMM controller is capturing the
communication satellite normally.
a The ORBCOMM terminal may take
3. Confirming VHMS controller operation and time to capture the satellite, depend-
confirming satellite capturing state ing on the strength of the signals from
a This work is done inside the cab. the satellite.
a Confirmation of capturing of the satellite is
done for [ORBCOMM installation specifi-
cation].
1) Turn the starting switch ON.
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
turned ON, the 7-segment LED must
blink to display rotation and then
count up in hexadecimal notation. If
the LED operates in this way, the – States of decimal point LED –
VHMS controller is operating nor- q OFF: The terminals cannot communi-
mally. cate with the ORBCOMM terminal.
q ON: Communication between VHMS
controller and ORBCOMM terminal is
normal. The terminals have not cap-
tured the satellite.
q Quick blink: Communication between
VHMS controller and ORBCOMM ter-
minal is normal. The ORBCOMM ter-
minal does not have any data to
transmit. It has captured the satellite.
HD465-7E0, HD605-7E0 5
q Slow blink: Communication between 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1

VHMS controller and ORBCOMM ter- or older version)
minal is normal. The ORBCOMM ter- a This work is done inside the cab (from
minal has data to transmit and it has PC).
captured the satellite. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
4. Starting the VHMS initial setting tool [Machine Information]
a This work is done inside the cab (from PC). 1) Open [Machine Information] tab.
1) Turn on the PC power and start the OS. a [Data clear and Set up] menu displays
2) Operating [VHMS initial setting tool] icon on [Machine Information] tab first.
the PC, start up the VHMS initial setting tool.
2) Check every data for correctness.
a The figure shows the display of another
Important
model as an example.
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
a When using Ver.3.5.2.1 or older ver-
sion (CD-ROM), the setting proce-
dure shall conform to that described
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. a Select a [Variation Code] from the fol-
5) Click [OK] button to proceed to the setup lowing table.
screen. 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.
6 HD465-7E0, HD605-7E0
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 – 7E0 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
when 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 payload meter
(PLM) function (Code: ST)".
a Since A and B of the short connector to be connected to connector No. HM-50 are not used, connect
them normally.
HD465-7E0, HD605-7E0 7
4) When [Machine Information] information is [Communication Setting] [ORBCOMM 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 ORBCOMM 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 ORBCOMM 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.
8 HD465-7E0, HD605-7E0
9) When modifying the setting of [SHORT

GCC
TREND ANALYSIS], employ the following Code
Area Remarks
procedure.
N.America (*1) *1: Except U.S. Territories in
1] Select [SHORT TREND ANALYSIS]
1 C.S.Americas Micronesia and Midway
from the screen and then press [Edit] Faroe Islands Island
button in the lower left side of [File
Europe (*2)
Transfer Setting] block to display the Middle East
setup screen. Asia (*3) *2: Except Faroe Islands
120
2] Correct the setting and, as it is com- Africa *3: Except Japan
pleted, press [OK] button. Oceania
a In the initial setting, enter [20h] to CIS
[SMR] and then set the function to 130 Japan
ON.
a If the combination of the country
name and code in the list box dis-
played by the setting tool is different
from the above table, select the GCC
code in the table or input the value
through the keyboard.
11) As every data in [Communication Setting]
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-
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 correc-
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
HD465-7E0, HD605-7E0 9
12) As every data in [Machine Information] 2) Select [Set up & All clear] and press [Next]
and [Communication Setting] has been button.
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].
3) Confirm the machine information and, if

they are correct, press [Next] button.
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1

or later version)
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.].
10 HD465-7E0, HD605-7E0
4) Select the time zone.

5) Enter the local time.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
8) If there is no problem in the setting dis-

played last, press [Apply] button.
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC
Area Remarks
Code
N.America (*1) *1: Except U.S. Territories in
1 C.S.Americas Micronesia and Midway
Faroe Islands Island
Europe (*2)
Middle East
Asia (*3) *2: Except Faroe Islands 9) A screen message will confirm whether or
120
Africa *3: Except Japan
not the data before the setting is to be
Oceania
CIS saved. If the data is not necessary, select
[NO].
130 Japan
a If the combination of the country
name and code in the list box dis-
played by the setting tool is different
from the above table, select the GCC
code in the table or input the value
through the keyboard.
HD465-7E0, HD605-7E0 11
10) As correction of the first setting is com- 4) Press the buzzer cancel switch [U].
pleted, press [OK] button to end the pro- 5) [READY] will be displayed on the screen,
gram. turning on the standby mode.
a The lower column displays 15 pieces
of [–] sign.
11) Turn the starting switch OFF.

Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
6) Press the buzzer cancel switch [U] to

start the snapshot.
a As the snapshot is started, the upper
column starts displaying the elapsed
time.
a [–] in the leftmost position of the lower
column is replaced with [*] for every
30 seconds. When two or more [*]
7. Executing quick Pm signs are displayed, the rightmost
a Quick Pm denotes the Pm click done by one flashes.
use of the manual snapshot function of the a When stopping the snapshot currently
machine monitor. taking place, press the buzzer cancel
a It stores 7 minutes and 30 seconds worth switch [t].
of data to VHMS controller.
k Park the machine in a flat place.

2) Switch the machine monitor to Service
menu.
a For the procedure of opening Service
menu, see "Special functions of
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-
perature are within the operating
range.
a After 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be dis-
played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
12 HD465-7E0, HD605-7E0
q #: Indicates the data sampling interval

is once every 1 second.
HD465-7E0, HD605-7E0 13
a Machine operation for snapshot

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

(*2) When stalling the torque converter [Portion marked with (*)], do not overheat it.
[Stall of torque converter for 30 seconds is only a reference. When the oil temperature gauge reaches the top of
the white range while the torque converter is stalled, return the transmission (gearshift) lever to the N position.]
(*3) When setting the gearshift lever in the D position, return the engine speed to low idle temporarily (to prevent the
machine from running out).
14 HD465-7E0, HD605-7E0
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 speed)
shall to PC. For the procedure, see 8. Down- q Shift Indicator (Gearshift position)
load of setting data. q Lock Up Signal (Lockup signal)
q Retarder Temp (Retarder oil tempera-
9) Read 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)
HD465-7E0, HD605-7E0 15
11) Apply a check mark to the Display graph

value at clicked position.
16 HD465-7E0, HD605-7E0
12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
displayed – Not an actual one)
HD465-7E0, HD605-7E0 17
8. Download of setting data

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

is installed to box (1) in 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 download connector VDL on
the ground, set switch (3) to ON position.
a The green LED will come on.
4) Operating [VHMS analysis tool] on PC,

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.
18 HD465-7E0, HD605-7E0
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 Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual. 2) As check of the setting data is finished,
a After making sure the download is end [VHMS analysis tool].
complete, proceed to the next step.
HD465-7E0, HD605-7E0 19
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, be sure to turn off the
starting switch.
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 setting report to VHMS/WebCARE
Support Center in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness N2 from download a When using the KOMTRAX functions on
connector DPC7. the machine equipped with the ORB-
COMM, complete the sign-up test on the
machine side and enter the use of the
KOMTRAX functions in the "VHMS/Web-
CARE setting notification form".
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 the data was download to the

ground, disconnect N2 from download
connector VDL.
20 HD465-7E0, HD605-7E0
[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
HD465-7E0, HD605-7E0 21
[For storage] Date of setting:

DB/branch
ORBCOMM 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.
ORBCOMM 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

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Using method of KOMTRAX q The ORBCOMM terminal is receiving

functions of ORBCOMM terminal1 the signals from the ORBCOMM
communication satellite. (The ORB-
COMM antenna is connected.)
a The ORBCOMM terminal equipped with the q Positioning of the machine with the is
KOMTRAX function can display the machine completed (The GPS antenna is con-
on the control screen of the KOMTRAX sys- nected.)
tem. 4) Check that LED1 is lighting.
a Whether the ORBCOMM terminal has the a At this time, the sign-up test is com-
KOMTRAX functions can be checked by the pleted.
part No. of the ORBCOMM terminal. a Once the sign-up test is completed,
q KOMTRAX functions provided: the ORBCOMM terminal cannot be
No. 7826-12-2500 returned to the original state.
q KOMTRAX functions not provided:
No. 7826-12-2302
a When using the KOMTRAX functions, perform
the following procedure.
1. Make the request for opening the ORBCOMM

terminal and receive the opening notification.
a See "Request for opening ORBCOMM ter-
minal".
2. Initialize the VHMS controller and set the GCC

code of the machine location.
a See "Initialization procedure for VHMS
controller".
3. Perform the sign-up test on the machine side.

a Perform the sign-up test in an open out-
door place.
a If the sign-up test is performed in an
indoor place where the satellite radio
waves are blocked, it may not be com-
pleted.
a It may take time to complete the sign-up
test, depending on the condition of receiv-
ing signals from the ORBCOMM commu-
nication satellite and GPS satellite.
1) Check that the VHMS controller, ORB-
COMM terminal, ORBCOMM antenna and
GPS antenna are connected to the wiring
harness of the machine.
2) Turn the starting switch to the ON position.
3) Wait until LED1 lights up.
a LED1 keeps flashing until the sign-up
test is completed.
a The ORBCOMM terminal executes
the sign-up test and judges the result
by itself. The criterion is as follows.
q The starting switch is in the ON posi-
tion.
q The VHMS controller can communi-
cate with the ORBCOMM terminal
(They are connected normally).
q A valid GCC code is set to the VHMS
controller.
24 HD465-7E0, HD605-7E0
[LED display] [State]

(1) LED-green KOMTRAX state Waiting for server trigger: Lighting
Normal operating state: Turning off
(2) LED-green ORBCOMM satellite capture Satellite not captured: Lighting
Satellite captured (No transmission data): Quick flashing
Satellite captured (There is transmission data): Slow flashing
Power OFF: Turning off
(3) LED-yellow VHMS start recognition VHMS start recognized: Lighting
VHMS stop recognized: Turning off
(4) LED-green ORBCOMM MODEM power ON: Lighting
OFF: Turning off
(5) LED-red Unused Kept Turning off
(6) LED-red Unused Kept Turning off
(7) 7-segment LED Number of mails waiting to be sent (Max. of 9)
(8) Dot GPS satellite capture state Satellite not captured: Turning off
Satellite captured: Lighting
* Flashing interval
Quick flashing: Period of 1 sec (Lighting for 0.5 sec and Turning off for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (Lighting for 2 sec and Turning off for 2 sec repeatedly)
HD465-7E0, HD605-7E0 25
4. Apply for starting to use.

1) Notify the VHMS/WebCARE operations
administrator of the following information
of the machine which has completed the
station set-up check.
q Model, model No. and serial No. of
machine
q Part No. and serial No. of ORBCOMM
terminal
q Reading of service meter when sign-
up test was completed (0.1 h unit)
2) Fill in the "VHMS/WebCARE setting notifi-
cation form" and enter "Use" in the column
of "Use of KOMTRAX Service".
3) Send the "VHMS/WebCARE setting notifi-
cation form" to VHMS/WebCARE Support
Center in Komatsu Head Office.
2-3-6, Akasaka Minato-ku Tokyo, Japan
E-mail: webcare@komatsu.co.jp
4) The KOMTRAX operations administrator

registers the machine using the KOM-
TRAX client personal computer.
a For the registration procedure, see
the "Global KOMTRAX Web Refer-
ence Manual (For Key Person)".
26 HD465-7E0, HD605-7E0
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 is saved from the
VHMS controller to be replaced to the PC
1 799-608-3211 Diskette and the saved information is loaded to the
2 799-608-3220 Wiring harness new VHMS controller after the replace-
N Note type PC ment.
Commercially (Windows 98/2000/Me/XP/ 2-1. Confirmation and saving of VHMS controller
3
available VISTA(*) and terminal setting information prior to replacement
"RS232C" is with it) 1) Connect the PC and start the VHMS initial
* : VHMS setting tool Ver.3.06.00.03 or later, setting tool.
VHMS analysis tool Ver.3.05.00.00 or later. a See the "VHMS controller initial set-
ting procedure" for this operation.
a When it is required to replace a VHMS control- 2) Select [Save/Load] and press [OK] button.
ler, setup of the replacing VHMS controller
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 3) Confirm every information before the
a This work is done inside the cab (from PC). replacement.
a Using [Download] function, download the 4) Select [Save] from [File] of the menu.
currently recorded and remained data on
VHMS to PC.
a For the operating procedure, refer to "8.
Download of setting data" in "VHMS con-
troller initial setting procedure".
HD465-7E0, HD605-7E0 27
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
a See the "VHMS controller initial set-
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-
lers.
28 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 29
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 is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller 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.
30 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 31
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).
2-3-6, Akasaka Minato-Ku Tokyo, 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.
32 HD465-7E0, HD605-7E0
Pm Clinic check sheet 1
HD465-7E0, HD605-7E0 33
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35
36 HD465-7E0, HD605-7E0
Initial setting of payload meter 1

In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS ini-
tialization 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 – 7E0 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 not a 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 machine is loaded and stopped", "There are not the manus
related to the payload meter on the match marks", 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.
HD465-7E0, HD605-7E0 37
Setting of payload meter built in VHMS 1

Outline of procedure
38 HD465-7E0, HD605-7E0
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 the load meter 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
HD465-7E0, HD605-7E0 39
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)
moves backward to 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 largest
position of the number to input
the value again. If this button is
pressed again, inputting of the
value is stopped and the previ-
ous screen appears.
q Inputtable range
HD465-7E0:
(metric ton)
HD605-7E0:
(metric ton)
40 HD465-7E0, HD605-7E0
6] Display the progress of measure- 5) Input the measured weight of the fully
ment. 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 the load meter and record it
(Write it on a sheet of paper, etc.)
q [U] button: Check that measure-

ment has been completed and
go to the next step
q [t] button: Return to the previ-
ous screen
HD465-7E0, HD605-7E0 41
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 largest utes (at a speed higher than 8 km/h)
position of the number to input to 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] Display the progress of measure-
ous screen appears. ment.
a Inputtable range
HD465-7E0:
A1 ± (A1 × 0.25) (metric ton)
However,
A1 = {43.1 [t] (Operating weight)
+ 46 [t] (Load capacity)}
HD605-7E0:
A2 ± (A2 × 0.25) (metric ton)
However,
A2 = {46.2 [t] (Operating weight)
+ 63 [t] (Load capacity)}
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
42 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 43
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
44 HD465-7E0, HD605-7E0
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 The load weight measured when the
rated 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), however. 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 by 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.
HD465-7E0, HD605-7E0 45
Setting of card-type payload meter (PLM- ) after installation or

replacement 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 HD465-7E0 Small size tire
7 HD465-7E0 Large size tire
A HD605-7E0 Large size tire
q Set weight unit setting switch (No. 7).
Position of switch Model
Upper Metric ton
Lower American ton (Short ton)
46 HD465-7E0, HD605-7E0
q Set buzzer volume switch (B) and switch forcible prohibition switch (No. 8), if necessary.
When changing these switches from the initial positions, be sure to check with the Operation
and Maintenance Manual.
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 HD465-7E0 and HD605-7E0, 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 transmission of data
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
HD465-7E0, HD605-7E0 47
3. Method of changing option code

1) Set the gearshift lever in "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.
48 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 49
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 (HD465-7E0, q XXX = Currently set display level
HD605-7E0), 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)
50 HD465-7E0, HD605-7E0

Display: E. XXX (E. lights up and
XXX blinks)
q XXX = Set to 105. (HD465-7E0)
q XXX = Set to 100. (HD605-7E.)
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.
HD465-7E0, HD605-7E0 51

© 2009 KOMATSU
All Rights Reserved
52 HD465-7E0, HD605-7E0
SEN01661-05
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
40 Troubleshooting 1
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-branch box and T-branch adapter table ..................................................................................................... 44
HD465-7E0, HD605-7E0 1
SEN01661-05 40 Troubleshooting
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 HD465-7E0, HD605-7E0
Sequence of events in troubleshooting 1
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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".
HD465-7E0, HD605-7E0 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 con-
nector 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 7
Connection table for connector pin numbers 1

(Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 9
10 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 11
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 13
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
26 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 27
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
32 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 33
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37
38 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 39
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
T-branch box and T-branch adapter table 1

(Rev. 2009.03)
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
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
799-601-4350 T-box (for DRC60, ECONO) 60 q
799-601-4360 Case 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
44 HD465-7E0, HD605-7E0
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
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 q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 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 (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
HD465-7E0, HD605-7E0 45
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for ECONO) 24 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* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Adapter for oil pressure
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket 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 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* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
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
799-601-4390* Socket for controller (95 ENG) 60 — 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
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2-4 and DTM2 3, — q
4
“ * ” Shows not T-adapter but socket.
46 HD465-7E0, HD605-7E0

© 2009 KOMATSU
All Rights Reserved
47 HD465-7E0, HD605-7E0
48 HD465-7E0, HD605-7E0
SEN01660-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 13
HD465-7E0, HD605-7E0 1
Failure codes table 1

Failure Applicable Action History Reference
Failure contents
codes equipment code classification manual
Mechanical
1500L0 Detection of double engagement TM E03 system
Mechanical
15B0NX Clogging of transmission oil filter TM E01 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 Electrical
TM E03
(command holding pressure, fill ON, detection of slip) system
Mechanical
15G7KM Abuse of transmission reverse clutch disk TM — system
Trouble in high clutch system Electrical
15H0MW TM E03
15J0MW Trouble in low clutch system Electrical
TM E03
15K0MW Trouble in 1st clutch system Electrical
TM E03
(command holding pressure, fill ON, detection of slip) system Troubleshooting
15L0MW Trouble in 2nd clutch system Electrical by failure code,
TM E03
(command holding pressure, fill ON, detection of slip) system Part 1
SEN01662-02
15M0MW Trouble in 3rd clutch system Electrical
TM E03
15N0MW Trouble in 4th clutch system Electrical
TM E03
15SBL1 Trouble I in reverse clutch pressure control valve Electrical
TM E03
(command OFF, fill ON) system
15SBMA Trouble II in reverse clutch pressure control valve Electrical
TM E03
(command holding pressure, fill OFF, detection of slip) system
15SCL1 Trouble I in high clutch pressure control valve Electrical
TM E03
15SCMA Trouble II in high clutch pressure control valve Electrical
TM E03
15SDL1 Trouble I in low clutch pressure control valve Electrical
TM E03
15SDMA Trouble II in low clutch pressure control valve Electrical
TM E03
15SEL1 Trouble I in 1st clutch pressure control valve Electrical
TM E03
15SEMA Trouble II in 1st clutch pressure control valve Electrical
TM E03
15SFL1 Trouble I in 2nd clutch pressure control valve Electrical
TM E03
15SFMA Trouble II in 2nd clutch pressure control valve Electrical
TM E03
15SGL1 Trouble I in 3rd clutch pressure control valve Electrical
TM E03
15SGMA Trouble II in 3rd clutch pressure control valve Electrical Troubleshooting
TM E03
(command holding pressure, fill OFF, detection of slip) system by failure code,
Part 2
15SHL1 Trouble I in 4th clutch pressure control valve Electrical
TM E03 SEN01663-03
15SHMA Trouble II in 4th clutch pressure control valve Electrical
TM E03
15SJMA Trouble II in lockup clutch pressure control valve Electrical
TM E03
(command holding pressure, detection of slip) system
Electrical
2C4MNX Clogging of retarder cooling oil filter BK E01 system
2 HD465-7E0, HD605-7E0

Failure contents
Mechanical
2F00KM Dragging of parking brake TM — system
Mechanical
2G42ZG Lowering of accumulator oil pressure (front) TM E03 system
Mechanical
2G43ZG Lowering of accumulator oil pressure (rear) TM E03 system
Mechanical
6014NX Clogging of hydraulic oil filter BK E01 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 MON —
sion controller and failure code is displayed on moni- system
tor panel)
Mechanical
A570NX Clogging of engine oil filter BK E01 system
Mechanical
AA10NX Clogging of air cleaner TM E01 Troubleshooting
system
by failure code,
Electrical Part 2
AB00MA Trouble in battery charge circuit (No R-terminal signal) TM E03 system SEN01663-03
Mechanical
B@BAZG Lowering of engine oil pressure ENG E03 system
Mechanical
B@BAZK Lowering of engine oil level BK E01 system
Mechanical
B@BCNS Overheating of engine ENG E02 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
Mechanical
B@CENS Overheating of torque converter oil MON E02 system
Mechanical
B@GAZK Lowering of battery electrolyte level BK E01 system
Mechanical
B@JANS Overheating of steering oil TM E02 system
Electrical
CA111 Abnormality in engine controller ENG E03 system
Electrical
CA115 Abnormality in engine Ne/Bkup speed sensor ENG E03 system
Electrical
CA122 Abnormally high level of charge pressure sensor ENG E03 system
Electrical
CA123 Abnormally low level of charge pressure sensor ENG E03 system
Electrical
CA131 Abnormally high level of throttle sensor ENG E03 system
Electrical Troubleshooting
CA132 Abnormally low level of throttle sensor ENG E03 system by failure code,
Electrical Part 3
CA135 Abnormally high level of oil pressure sensor ENG E01 SEN01664-04
system
Electrical
CA141 Abnormally low level of oil pressure sensor ENG E01 system
Electrical
CA144 Abnormally high level of coolant temperature sensor ENG E01 system
Electrical
CA145 Abnormally low level of coolant temperature sensor ENG E01 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
HD465-7E0, HD605-7E0 3

Failure contents
Electrical
CA187 Abnormally low level of sensor power supply 2 ENG E03 system
Abnormally high level of engine oil temperature Electrical
CA212 ENG E01
sensor (for VHMS) system
Abnormally low level of engine oil temperature sensor Electrical
CA213 ENG E01
(for VHMS) system
Electrical
CA221 Abnormally high level of ambient temperature sensor ENG E01 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
Electrical
CA263 Abnormally high level of fuel temperature sensor ENG E01 system
Electrical
CA265 Abnormally low level of fuel temperature sensor ENG E01 system
Electrical
CA271 Short circuit in PCV1 ENG E03 system
CA272 Disconnection in PCV1 ENG E03 system by failure code,
Electrical Part 3
CA273 Short circuit in PCV2 ENG E03 SEN01664-04
system
Electrical
CA274 Disconnection in PCV2 ENG E03 system
Electrical
CA322 Disconnection or short circuit in injector #1 system ENG E03 system
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
CA342 Abnormality in matching of engine controller data ENG E03 system
Electrical
CA351 Abnormality in injector drive circuit ENG E03 system
Electrical
CA352 Abnormally low level of sensor power supply 1 ENG E03
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
CA432 Abnormality in idle validation setting ENG E03 system
Electrical
CA441 Abnormally low level of source voltage ENG E03 system Troubleshooting
Electrical by failure code,
CA442 Abnormally high level of source voltage ENG E03 system Part 4
Electrical SEN01665-04
CA449 Abnormality 2 in common rail high pressure ENG E03 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
4 HD465-7E0, HD605-7E0

Failure contents
Electrical
CA553 Abnormality 1 in common rail high pressure ENG E03 system
Electrical
CA554 In-range trouble of common rail pressure sensor ENG E03 system
Electrical
CA559 Lowering 1 of supply pump pressure ENG E03 system
Electrical
CA689 Abnormality in engine Ne speed sensor ENG E03 system
Electrical
CA731 Abnormality in engine Bkup speed sensor phase ENG E03 system
Electrical
CA757 Loss of all engine controller data ENG E03 system
Electrical
CA778 Abnormality in engine Bkup speed sensor ENG E03 system
Electrical
CA1228 Abnormality 1 in EGR valve servo ENG E03 system
Electrical
CA1625 Abnormality 2 in EGR valve servo ENG E03 system
Electrical
CA1626 Short circuit in bypass valve solenoid drive system ENG E03 system
Electrical
CA1627 Disconnection in bypass valve solenoid drive system ENG E03 system
Electrical
CA1628 Abnormality 1 in bypass valve servo ENG E03 system Troubleshooting
CA1629 Abnormality 2 in bypass valve servo ENG E03 system Part 4
CA1631 Abnormally high level of bypass valve lift sensor ENG E03 system
Electrical
CA1632 Abnormally low level of bypass valve lift sensor ENG E03 system
Electrical
CA1633 Abnormality in KOMNET ENG E03 system
Electrical
CA2185 Abnormally high level of throttle sensor power supply ENG E03 system
Electrical
CA2186 Abnormally low level of throttle sensor power supply ENG E03 system
Electrical
CA2249 Lowering 2 of supply pump pressure ENG E03 system
Electrical
CA2271 Abnormally high level of EGR valve lift sensor ENG E03 system
Electrical
CA2272 Abnormally low level of EGR valve lift sensor ENG E03 system
Electrical
CA2351 Short circuit in EGR valve solenoid drive ENG E03 system
Electrical
CA2352 Disconnection in EGR valve solenoid drive ENG E03 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
D19HKB Trouble in stop lamp relay output system Electrical
BK E01 system
Electrical
D5ZKKZ Trouble in front brake cut valve system BK E01 system
DAF9KM Wrong connection of connector MON E03 by failure code,
system
Part 5
(DAFRKR) Abnormality in CAN communication (monitor panel) TM — — SEN01666-03
Electrical
DAQ0KK Lowering of source voltage TM E03 system
Electrical
DAQ0KT Abnormality in non-volatile memory TM E01 system
HD465-7E0, HD605-7E0 5

Failure contents
Electrical
DAQ2KK Trouble in solenoid power supply system TM E03 system
(DAQ9KQ) Disagreement of model selection signals MON E03 —
DAQRKR Abnormality in CAN communication (transmission Electrical
MON E03
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 Electrical
TM E03
(retarder controller) system
(DB1RMA) Disagreement of option setting (brake) MON E03 —
DB2RKR Abnormality in CAN communication Electrical
TM E03
(engine controller) system
VHMS
DBB0KK VHMS controller (Low source voltage (input)) Electrical
(indication: — system
PLM)
VHMS
DBB0KQ VHMS controller (Disagreement of model selection Electrical
signal) (indication: — system
PLM)
VHMS
DBB3KK VHMS controller battery power supply (Low source Electrical
voltage (input)) (indication: — system
PLM)
VHMS
DBB5KP VHMS controller 5 V power supply output (Low output (indication: — Electrical
voltage) system Troubleshooting
PLM) by failure code,
VHMS Part 5
DBB6KP VHMS controller 24 V power supply output (Low out- Electrical SEN01666-03
put voltage) (indication: — system
PLM)
VHMS
DBB7KP VHMS controller 12 V power supply output (Low out- Electrical
put voltag) (indication: — system
PLM)
VHMS
DBBQKR VHMS controller CAN communication (Defective com- (indication: — Electrical
munication (Abnormality in target component system)) PLM) 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 —
Electrical
DBCRKR Abnormality in CAN communication (ABS) TM E03 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
Electrical
DDD9KB Short circuit in ABS system switch ABS E03 system
Electrical
DDDAKA Disconnection in ASR system switch BK E01 system
6 HD465-7E0, HD605-7E0

Failure contents
Electrical
DDDAKB Short circuit in ASR system switch BK E01 system
Electrical
DDP6L4 Trouble in service brake pressure switch ABS E03 system
Trouble in high clutch flow sensor valve Electrical
DDTHKA TM E03
(command holding pressure, fill OFF, no slip) system
Trouble in low clutch flow sensor valve Electrical
DDTJKA TM E03
Trouble in 1st clutch flow sensor valve Electrical
DDTKKA TM E03
Trouble in 2nd clutch flow sensor valve Electrical
DDTLKA TM E03
Trouble in 3rd clutch flow sensor valve Electrical
DDTMKA TM E03
Trouble in reverse clutch flow sensor valve Electrical
DDTNKA TM E03 Troubleshooting
by failure code,
Trouble in 4th clutch flow sensor valve Electrical Part 5
DDTPKA TM E03
(command holding pressure, fill OFF, no slip) system SEN01666-03
Electrical
DF10KA Input of no lever signal TM E03 system
DF10KB Input of multiple lever signal TM E03 Electrical
system
VHMS
Atmospheric temperature senso (Out of input signal Electrical
DGE5KX (indication: —
range) system
PLM)
Transmission oil temperature sensor input signal out Electrical
DGF1KX TM E03
of range system
Trouble in retarder oil temperature sensor (rear wheel) Electrical
DGR2KZ BK E01
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 TM E01
out of range system
VHMS
DGT4KA Exhaust gas temperature sensor (F) (Disconnection) (indication: Electrical
— system
PLM)
VHMS Electrical
DGT4KB Exhaust gas temperature sensor (F): (Short circuit) (indication: — system
PLM)
VHMS
DGT5KA Exhaust gas temperature sensor (R): (Disconnection) (indication: Electrical
— system
PLM)
VHMS
DGT5KB Exhaust gas temperature sensor (R): (Short circuit) Electrical
PLM)
VHMS Electrical
DHE5KB Blow-by pressure sensor (Short circuit) (indication: — system Troubleshooting
PLM) by failure code,
VHMS Part 6
Blow-by pressure sensor (Short circuit with power Electrical SEN01667-04
DHE5KY (indication: —
supply line) system
PLM)
VHMS
Short circuit in suspension pressure sensor system Electrical
DHP4KY (indication: E01
(front right) system
PLM)
VHMS
Disconnection or ground fault in suspension pressure (indication: Electrical
DHP4KZ E01
sensor system (front right) PLM) system
VHMS
(front left) system
PLM)
VHMS
Disconnection or ground fault in suspension pressure Electrical
DHP5KZ (indication: E01
sensor system (front left) system
PLM)
HD465-7E0, HD605-7E0 7

Failure contents
Trouble in suspension pressure sensor system Electrical
DHP6KA BK E01
(rear right) system
DHP6KX BK E03
(rear right) system
VHMS
(rear right) system
PLM)
VHMS
sensor system (rear right) system
PLM)
DHP7KA BK E01
(rear left) system
DHP7KX BK E03
(rear left) system
VHMS
(rear left) system
PLM)
VHMS
sensor system (rear left) system
PLM)
Disconnection, ground fault or hot short in torque Electrical
DHT5KX TM E01
converter inlet oil pressure sensor system
Electrical
DHT5L6 Trouble in torque converter inlet oil pressure sensor TM E01 system
Electrical
DHU2KX Trouble in accumulator oil pressure sensor (front) TM E01 system
Electrical
DHU3KX Trouble in accumulator oil pressure sensor (rear) TM E01 system
Trouble in ABS control valve pressure sensor Electrical
DHU6KX ABS E03
(front right) system
Trouble in ABS control valve pressure sensor Electrical Troubleshooting
DHU7KX ABS E03 by failure code,
(front left) system
Part 6
DHU8KX ABS E03 SEN01667-04
(rear right) system
DHU9KX ABS E03
(rear left) system
Electrical
DJF1KA Disconnection in fuel level sensor system TM E01 system
Electrical
DK30KX Trouble in steering angle potentiometer BK E01 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
Electrical
DK54KX Trouble in boom positioner sensor BK E03 system
Electrical
DKD0L6 Trouble in steering speed sensor BK E01 system
Electrical
DKH0KX Clinometer sensor signal out of range TM E01 system
VHMS
DKH1KX Abnormality in clinometer sensor Electrical
(indication: E01 system
PLM)
Disconnection in transmission input shaft speed Electrical
DLF1KA TM E03
sensor system system
Electrical
DLF1LC Trouble in transmission input shaft speed sensor TM E03 system
Disconnection in transmission intermediate shaft Electrical
DLF2KA TM E03
speed sensor system system
Trouble in transmission intermediate shaft speed Electrical
DLF2LC TM E03
sensor system
8 HD465-7E0, HD605-7E0

Failure contents
Electrical
DLF6KA Disconnection in wheel speed sensor (front right) ABS E03 system
Electrical
DLF6L3 Trouble in wheel speed sensor (front right) ABS E03 system
Electrical
DLF7KA Disconnection in wheel speed sensor (front left) ABS E03 system
Electrical
DLF7L3 Trouble in wheel speed sensor (front left) ABS E03 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
Electrical
DLF9KA Disconnection in wheel speed sensor (rear left) BK E01 system
Electrical
DLF9L3 Trouble in wheel speed sensor (rear left) ABS E03 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 TM E03
sensor system system
Electrical
DLT3LC Trouble in transmission output shaft sensor BK E01 system
Disconnection in transmission output shaft speed Electrical
DLT4KA BK E01
sensor system Troubleshooting
Disconnection in transmission output shaft speed Electrical by failure code,
DLT4MA BK E03
sensor system Part 7
DV00KB Short circuit in buzzer output MON E01 system
Electrical
DW2AKA Disconnection in main pressure variable valve output TM E01 system
DW2AKB Ground fault in main pressure variable valve output Electrical
TM E01
circuit system
Electrical
DW2AKY Hot short in main pressure variable valve output circuit TM E01 system
Electrical
DW2AL1 Defective reset of main pressure variable valve TM E01 system
Electrical
DW2ALH Malfunction of main pressure variable valve TM E01 system
DW35KZ Trouble in auto-suspension solenoid 1 output system Electrical
BK E01
(disconnection or ground fault) system
Trouble in auto-suspension solenoid 2 output system Electrical
DW36KZ BK E01
Trouble in kick-out solenoid output system Electrical
DW72KZ BK E01
Trouble (disconnection or ground fault) in hoist selec- Electrical
DW73KZ BK E03
tor valve output system (disconnection or ground fault) system
Electrical
DW78KZ Trouble in BCV output system BK E01 system
Electrical
DWNBK4 Trouble in ASR shut-off valve (valve keeps operating) BK E01 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
HD465-7E0, HD605-7E0 9

Failure contents
Electrical
DWNBMA Trouble in ASR shut-off valve (valve does not operate) BK E01 system
Electrical
DWNDKZ Trouble in ABS cut valve (front) system ABS E03 system Troubleshooting
DWNDMA Defective ABS cut valve (front) ABS E03 system Part 7
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 BK E03
solenoid valve (valve keeps operating) system
Disconnection in rear wheel proportional pressure Electrical
DX11KA BK E03
reducing solenoid valve output circuit system
Ground fault in rear wheel proportional pressure Electrical
DX11KB BK E03
Short circuit in rear wheel proportional pressure Electrical
DX11KY BK E03
Trouble in rear wheel proportional pressure reducing Electrical
DX11MA BK E03
solenoid valve (valve does not operate) system
DX13KA Disconnection in hoist EPC valve output circuit BK E03 Electrical
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
Trouble in ASR proportional pressure reducing Electrical
DX17K4 BK E01
solenoid valve (right) (valve keeps operating) system
Disconnection in ASR proportional pressure reducing Electrical
DX17KA BK E01
solenoid valve (right) output circuit system
Ground fault in ASR proportional pressure reducing Electrical
DX17KB BK E01
Short circuit in ASR proportional pressure reducing Electrical
DX17KY BK E01
Trouble in ASR proportional pressure reducing Electrical Troubleshooting
DX17MA BK E01
solenoid valve (right) (valve does not operate) system by failure code,
Trouble in ASR proportional pressure reducing Electrical Part 8
DX18K4 BK E01 SEN01669-02
solenoid valve (left) (valve keeps operating) system
Disconnection in ASR proportional pressure reducing Electrical
DX18KA BK E01
solenoid valve (left) output circuit system
Ground fault in ASR proportional pressure reducing Electrical
DX18KB BK E01
Short circuit in ASR proportional pressure reducing Electrical
DX18KY BK E01
Trouble in ASR proportional pressure reducing Electrical
DX18MA BK E01
solenoid valve (left) (valve does not operate) system
Disconnection in ABS control valve (front right) output Electrical
DX21KA ABS E03
circuit system
Ground fault in ABS control valve (front right) output Electrical
DX21KB ABS E03
circuit system
Short circuit in ABS control valve (front right) output Electrical
DX21KY ABS E03
circuit system
Electrical
DX21MA Defective ABS control valve (front right) ABS E03 system
Disconnection in ABS control valve (front left) output Electrical
DX22KA ABS E03
circuit system
Ground fault in ABS control valve (front left) output Electrical
DX22KB ABS E03
circuit system
Short circuit in ABS control valve (front left) output Electrical
DX22KY ABS E03
circuit system
Electrical
DX22MA Defective ABS control valve (front left) ABS E03 system
10 HD465-7E0, HD605-7E0

Failure contents
Disconnection in ABS control valve (rear right) output Electrical
DX23KA ABS E03
circuit system
Ground fault in ABS control valve (rear right) output Electrical
DX23KB ABS E03
circuit system
Short circuit in ABS control valve (rear right) output Electrical
DX23KY ABS E03
circuit system
Electrical
DX23MA Defective ABS control valve (rear right) ABS E03 system
Disconnection in ABS control valve (rear left) output Electrical Troubleshooting
DX24KA ABS E03
circuit system by failure code,
Ground fault in ABS control valve (rear left) output Electrical Part 8
DX24KB ABS E03 SEN01669-02
circuit system
Short circuit in ABS control valve (rear left) output Electrical
DX24KY ABS E03
circuit system
Electrical
DX24MA Defective ABS control valve (rear left) ABS E03 system
Electrical
DX25MA Defective ABS front wheel system control valve ABS E03 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
Electrical
DXH1KY Hot short in lockup clutch solenoid output circuit TM E03 system
Electrical
DXH2KA Disconnection in high clutch solenoid output circuit TM E03 system
Electrical
DXH2KB Ground fault in high clutch solenoid output circuit TM E03 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
Electrical
DXH3KB Ground fault in low clutch solenoid output circuit TM E03 system
Electrical
DXH3KY Hot short in low clutch solenoid output circuit TM E03 system
Electrical
DXH4KA Disconnection in 1st clutch solenoid output circuit TM E03 Troubleshooting
system
DXH4KB Ground fault in 1st clutch solenoid output circuit TM E03 Part 9
system
SEN01670-02
DXH4KY Hot short in 1st clutch solenoid output circuit Electrical
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
Electrical
DXH5KY Hot short in 2nd clutch solenoid output circuit TM E03 system
Electrical
DXH6KA Disconnection in 3rd clutch solenoid output circuit TM E03 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
Electrical
DXH7KB Ground fault in reverse clutch solenoid output circuit TM E03 system
Electrical
DXH7KY Hot short in reverse clutch solenoid output circuit TM E03 system
HD465-7E0, HD605-7E0 11

Failure contents
Electrical
DXHHKA Disconnection in 4th clutch solenoid output circuit TM E03 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
VHMS
F@BBZL Blow-by pressure (High error) Electrical
PLM) Troubleshooting
VHMS by failure code,
Electrical Part 9
F@BYNR Exhaust gas temperature (F) (Abnormal heat) (indication: — system
PLM) SEN01670-02
VHMS
F@BYNS Exhaust gas temperature (F) (Overheat) Electrical
PLM)
VHMS
F@BZNR Exhaust gas temperature (R) (Abnormal heat) Electrical
PLM)
VHMS
F@BZNS Exhaust gas temperature (R) (Overheat) Electrical
PLM)
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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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-13".
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 17

© 2009 KOMATSU
All Rights Reserved
18 HD465-7E0, HD605-7E0
SEN01662-02
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 code Failure code R o F shifting abuse 2: Mistake in operation
Trouble
— 15F0MB (Transmission controller system)
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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)
(Transmission controller system)
• 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 A1 (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 R.PS (CN12).
1 Defective R clutch ECMV Resis-
Between R.PS (CN12) (male) (1) – (2) 5 – 15 z
tance
Between R.PS (CN12) (male) (1), (2) – Resis-
Min. 1 Mz
ground tance
Possible causes 2) Disconnect connectors ATC3 and R.PS (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
– R.PS (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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

2) Disconnect connector H.PS (CN19).
1 Defective Hi clutch ECMV Resis-
Between H.PS (CN19) (male) (1) – (2) 5 – 15 z
tance
Between H.PS (CN19) (male) (1), (2) – Resis-
Min. 1 Mz
ground tance
Possible causes 2) Disconnect connectors ATC3 and H.PS (CN19).
– H.PS (CN19) (female) (1) tance
contact)
Max. 1 z
sensor
4
troller
5 – 15 z
12 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

2) Disconnect connector L.PS (CN17).
1 Defective Lo clutch ECMV Resis-
Between L.PS (CN17) (male) (1) – (2) 5 – 15 z
tance
Between L.PS (CN17) (male) (1), (2) – Resis-
Min. 1 Mz
ground tance
Possible causes 2) Disconnect connectors ATC3 and L.PS (CN17).
– L.PS (CN17) (female) (1) tance
contact)
Max. 1 z
sensor
4
troller
5 – 15 z
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 A1 (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 1.PS (CN6) (male).
Resis-
1 Defective 1st clutch ECMV Between 1.PS (CN6) (male) (1) – (2) 5 – 15 z
tance
Between 1.PS (CN6) (male) (1), (2) – Resis-
Min. 1 Mz
ground tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and 1.PS
and standard Disconnection in wiring (CN6) (female).
– 1.PS (CN6) (female) (1) tance
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 2.PS (CN8) (male) (1) – (2) 5 – 15 z
tance
Between 2.PS (CN8) (male) (1), (2) and Resis-
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
18 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 3.PS (CN10) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
20 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 4.PS (CN14) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
22 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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.

2) Connect T-adapter to connector R.SW (CN13) (male).
When R
Resis-
Defective for R clutch fill is disen- Min. 1 Mz
1 tance
switch Between R.SW (CN13) (male) gaged
(1) – ground When R
Resis-
is Max. 1 z
tance
engaged
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect connectors ATC3 and R.SW (CN13).
value in normal Defective harness grounding 3) Connect T-adapter to ATC3 (female).
2
state (Contact with ground circuit)
Min. 1 Mz
– R.SW (CN13) (female) (1) tance
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector R.PS (CN12) (male).
Resis-
1 Defective R clutch ECMV Between R.PS (CN12) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and R.PS
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
26 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 signal 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

2) Connect T-adapter to connector H.SW (CN20) (male).
When Hi
Resis-
is disen- Min. 1 Mz
1 Defective Hi clutch fill switch tance
Between H.SW (CN20) (male) gaged
(1) – ground When Hi
Resis-
is Max. 1 z
tance
engaged
Possible causes
2) Disconnect connectors ATC3 and H.SW (CN20).
and standard
2
state (Contact with ground circuit) Between ground and wiring harness
Resis-
between ATC3 (female) (30) – H.SW Min. 1 Mz
tance
(CN20) (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 HD465-7E0, HD605-7E0
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 —
HD465-7E0, HD605-7E0 29
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector H.PS (CN19) (male).
Resis-
1 Defective Hi clutch ECMV Between H.PS (CN19) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and H.PS
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
32 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector L.SW (CN18) (male).
When Lo
Resis-
is Min. 1 Mz
1 Defective Lo clutch fill switch tance
Between L.SW (CN18) (male) released
(1) – ground When Lo
Resis-
is Max. 1 z
tance
engaged
Possible causes
2) Disconnect connectors ATC3 and L.SW (CN18).
and standard
2
Resis-
between ATC3 (female) (10) – L.SW (CN18) Min. 1 Mz
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 35
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector L.PS (CN17) (male).
Resis-
1 Defective Lo clutch ECMV Between L.PS (CN17) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and L.PS
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
38 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector 1.SW (CN7) (male).
When 1st
Resis-
is Min. 1 Mz
1 Defective 1st clutch fill switch tance
Between 1.SW (CN7) (male) (1) released
– ground When 1st
Resis-
is Max. 1 z
tance
engaged
Possible causes
2) Disconnect connectors ATC3 and 1.SW (CN7).
and standard
2
Resis-
between ATC3 (female) (40) – 1.SW (CN7) Min. 1 Mz
tance
(female) (1)
When 1st
Resis-
3 tance
ground When 1st
Resis-
is Max. 1 z
tance
engaged
40 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 41
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
44 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 45

© 2008 KOMATSU
All Rights Reserved
46 HD465-7E0, HD605-7E0
SEN01663-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
(Fill signal is ON though command current is OFF)................................................................................. 3
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve
(Though command is holding pressure, 2nd clutch fill switch is OFF, and slipping detected) ................. 6
(Fill signal is ON though command current is OFF)................................................................................. 8
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve
(Though command is holding pressure, 3rd clutch fill switch is OFF, and slipping detected) ................ 12
(Fill signal is ON though command current is OFF)............................................................................... 14
Failure code [15SHMA] Trouble in 4th clutch pressure control valve
(Though command is holding pressure, 4th clutch fill switch is OFF, and slipping detected) ................ 18
Failure code [15SJMA] Trouble in lockup clutch pressure control valve
(Though lockup command is holding pressure, slipping is detected) .................................................... 20
Failure code [2C4MNX] Retarder cooling oil filter: Clogging......................................................................... 22
Failure code [2F00KM] Parking brake: Dragging.......................................................................................... 24
HD465-7E0, HD605-7E0 1
Failure code [2G42ZG] Lowering of accumulator oil pressure (Front) .......................................................... 27

Failure code [2G43ZG] Lowering of accumulator oil pressure (Rear)........................................................... 27
Failure code [6014NX] Hydraulic oil filter: Clogging...................................................................................... 28
Failure code [989A00] Operation of engine overrun prevention device
and failure code is displayed on monitor panel)..................................................................................... 30
Failure code [989D00] Inclination alarm (Raising body while machine is inclined)
and failure code is displayed on monitor panel).................................................................................... 30
Failure code [A570NX] Engine oil filter: Clogging ......................................................................................... 31
Failure code [AA10NX] Air cleaner: Clogging ............................................................................................... 32
Failure code [AB00MA] Trouble in battery charge circuit (No R-terminal signal from alternator).................. 34
Failure code [B@BAZG] Lowering of engine oil pressure............................................................................. 36
Failure code [B@BAZK] Lowering of engine oil ............................................................................................ 38
Failure code [B@BCNS] Engine overheat .................................................................................................... 40
Failure code [B@BCZK] Coolant level low alarm.......................................................................................... 42
Failure code [B@BFZK] Lowering of fuel level ............................................................................................. 44
Failure code [B@C7NS] Overheating of brake cooling oil (Rear) ................................................................. 46
Failure code [B@CENS] Overheating of torque converter oil ....................................................................... 48
Failure code [B@GAZK] Lowering of battery electrolyte level ...................................................................... 49
Failure code [B@JANS] Overheating of steering oil ..................................................................................... 50
2 HD465-7E0, HD605-7E0

(Fill signal is ON though command current is OFF) 1
Action code Failure code Trouble in 2nd clutch pressure control valve
Trouble (Fill signal is ON though command current is OFF)
E03 15SFL1
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 2.SW (CN9) (male) (1) released
– ground When 2nd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard Grounding fault in wiring 3) Connect T-adapter to ATC3 (female).
value in normal 2 harness
state (Contact with ground circuit) Between ground and wiring harness Resis-
tance
(female) (1)
When 2nd
Resis-
3 tance
ground When 2nd
Resis-
is Max. 1 z
tance
engaged
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve

(Though command is holding pressure, 2nd clutch fill switch is OFF,
and slipping detected) 1
Action code Failure code Trouble in 2nd clutch pressure control valve
Trouble (Though command is holding pressure, 2nd clutch fill switch is
E03 15SFMA OFF, and slipping 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
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
controller Wiring harness between ACT3 (female) (5) Resis-
5 – 15 z
– (23) tance
6 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 7

Action code Failure code Trouble in 3rd clutch pressure control valve
E03 15SGL1
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 3.SW (CN11) (male) released
(1) – ground When 3rd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard Grounding fault in wiring 3) Connect T-adapter to ATC3 (female).
value in normal 2 harness
state (Contact with ground circuit) Between ground and wiring harness Resis-
tance
(female) (1)
When 3rd
Resis-
3 tance
ground When 3rd
Resis-
is Max. 1 z
tance
engaged
8 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 9
10 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 11
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve

(Though command is holding pressure, 3rd clutch fill switch is OFF, and
slipping detected) 1
Action code Failure code Trouble in 3rd clutch pressure control valve
Trouble (Though command is holding pressure, 3rd clutch fill switch is OFF,
E03 15SGMA and slipping 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
Min. 1 Mz
ground tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
12 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 13

Action code Failure code Trouble in 4th clutch pressure control valve
E03 15SHL1
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

2) Disconnect connector 4.SW (CN15).
1 Defective 4th clutch fill switch When dis- Resis-
Min. 1 Mz
Between 4.SW (CN15) (male) engaged tance
(1) – ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
Grounding fault in wiring 3) Connect T-adapter to ATC3 (female).
value in normal 2
state harness Between ground and wiring harness
Resis-
tance
(female) (1)
3 When dis- Resis-
controller Min. 1 Mz
Between ATC3 (female) (20) – engaged tance
ground When Resis-
Max. 1 z
engaged tance
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 15
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
Failure code [15SHMA] Trouble in 4th clutch pressure control valve

(Though command is holding pressure, 4th clutch fill switch is OFF, and
slipping detected) 1
Action code Failure code Trouble in 4th clutch pressure control valve
Trouble (Though command is holding pressure, 4th clutch fill switch is OFF,
E03 15SHMA and 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 • 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.

2) Disconnect connector 4.PS (CN14).
1 Defective 4th clutch ECMV Resis-
Between 4.PS (CN14) (male) (1) – (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
Possible causes 2) Disconnect connectors ATC3 and 4.PS (CN14).
contact)
Max. 1 z
Defective detection speed
sensor
4
troller
5 – 15 z
– (3) tance
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19
Failure code [15SJMA] Trouble in lockup clutch pressure control

valve (Though lockup command is holding pressure, slipping is
detected) 1
Action code Failure code Trouble in lockup clutch pressure control valve
Trouble (Though lockup command is holding pressure, slipping is detected)
E03 15SJMA
• 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.

2) Connect T-adapter to connector L/U.PS (CN16) (male).
Defective lockup clutch Resis-
1 Between L/U.PS (CN16) (male) (1) – (2) 5 – 15 z
solenoid tance
Between L/U.PS (CN16) (male) (1), (2) – Resis-
Min. 1 Mz
ground tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and L/U.PS
– L/U.PS (CN16) (female) (1) tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 1

Action code Failure code Retarder cooling oil filter: Clogging
Trouble
E01 2C4MNX (Retarder controller system)
Contents of
• The retarder cooling oil filter signal circuit was open (disconnected from ground circuit).
trouble
Action of
• None in particular
controller
Problem that
appears on • If the retarder is used for long hours, it may be seized.
machine
Related
information

Retarder cooling oil filter is
1 The oil filter is probably clogged.
clogged
2) Disconnect connector BCF.
Defective switch for the BCF Oil filter Resistance
2 retarder cooling oil filter
clogging When normal Max. 1 z
Between (1) – (2) When the clogging
Min. 1 Mz
switch is open
Possible causes
and standard 1) Turn the starting switch OFF.
Disconnection in wiring 2) Disconnect connector BRC2 and BRC1.
state 3 3) Connect T-branch to BRC1 and BRC2 (female).
(Disconnection or defective
Wiring harness between BRC2 (female) Resis-
contact) Max. 1 z
(17) – BRC1 (female) (6) tance
2) Connect T-branch to connector BRC2.
4 Defective retarder controller BRC2 Oil filter Voltage
When normal Max. 1 V
Between (17) –
chassis ground When the clogging
20 – 30 V
switch is open
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Failure code [2F00KM] Parking brake: Dragging 1

Action code Failure code Parking brake: Dragging
Trouble
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)
24 HD465-7E0, HD605-7E0

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).
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 in wiring 3) Connect T-adapter.
6
state harness
Between wiring harness BRC3 (female) (9), Resis-
Min. 1 Mz
R03 (female) (3) and 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
HD465-7E0, HD605-7E0 25
26 HD465-7E0, HD605-7E0
Failure code [2G42ZG] Lowering of accumulator oil pressure (Front) 1

Action code Failure code Lowering of accumulator oil pressure (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] Lowering of accumulator oil pressure (Rear) 1

Action code Failure code Lowering of accumulator oil pressure (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].
HD465-7E0, HD605-7E0 27
Failure code [6014NX] Hydraulic oil filter: Clogging 1

Action code Failure code Hydraulic oil filter: Clogging
Trouble
E01 6014NX (Retarder controller system)
Contents of
• The oil filter signal circuit was open (disconnected from ground circuit).
trouble
Action of
controller
Problem that
appears on • Each pump may be seized if they are used for long time.
machine
Related
information

1 Clogging of hydraulic oil filter The oil filter is probably clogged.
2) Disconnect connector HDF.
Defective switch for the HDF Oil filter Resistance
2
hydraulic oil filter clogging When normal Max. 1 z
Between (1) – (2) When the clogging
Min. 1 Mz
switch is open
and standard Disconnection in wiring 2) Disconnect connector BRC2 and BRC1.
value in normal harness 3) Connect T-branch to BRC1 and BRC2 (female).
3
state (Disconnection or defective
Wiring harness between BRC2 (female) (2) Resis-
contact) Max. 1 z
–BRC1 (female) (6) tance
2) Connect T-branch to connector BRC2.
Between (2) –
chassis ground When the clogging
20 – 30 V
switch is open
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29
Failure code [989A00] Operation of engine overrun prevention device

(Note: Information is obtained from transmission controller and failure
code is displayed on monitor panel) 1
Action code Failure code Operation of engine overrun prevention device
(Note: Information is obtained from transmission controller and fail-
Trouble
E02 989A00 ure code is displayed on monitor panel)
(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
• Sends out command signal to retarder controller and activates brake.
controller
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] Inclination alarm (Raising body while machine is

inclined) (Note: Information is obtained from transmission controller
and failure code is displayed on monitor panel) 1
Action code Failure code Inclination alarm (Raising body while machine is inclined)
(Note: Information is obtained from transmission controller and fail-
Trouble
— 989D00 ure code is displayed on monitor panel)
(Machine monitor system)
Contents of
• Body is lifted when machine is inclined.
trouble
Action of • Turns on inclination caution lamp
controller • 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
30 HD465-7E0, HD605-7E0
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.
Between (13) – ground When clogging
20 – 30 V
switch is open
HD465-7E0, HD605-7E0 31
Failure code [AA10NX] Air cleaner: Clogging 1

Action code Failure code Air cleaner: 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.
Relay (R03) is
When the dust indicator relay No
normal
(R32) is replaced, is failure
repaired? Relay (R03) is
Yes
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
ging sensor a Inside of air cleaner sensor is consist of electric circuit,so it is
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
32 HD465-7E0, HD605-7E0

2) Disconnect connectors R32 and FR01.
Grounding fault in wiring har- 3) Connect T-adapter.
5
Possible causes ness
Between wiring harness R32 (female) (2) – Resis-
and standard Min. 1 Mz
FR01 (female) (1) and 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
HD465-7E0, HD605-7E0 33
Failure code [AB00MA] Trouble in battery charge circuit

(No R-terminal signal from alternator) 1
Action code Failure code Trouble in battery charge circuit
Trouble (No R-terminal signal from alternator)
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.
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35
Failure code [B@BAZG] Lowering of engine oil pressure 1

Action code Failure code Lowering of engine 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 • Limits output for travel (Limits 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
Wiring harness between ENG (female) (13) Resis-
value in normal Max. 1 z
state – POIL (female) (3) tance
Between wiring harness ENG (female) (37) Resis-
Grounding fault in wiring har- – POIL (female) (1) and ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Between wiring harness ENG (female) (47) Resis-
Min. 1 Mz
– POIL (female) (2) and ground tance
Between wiring harness ENG (female) (13) Resis-
Min. 1 Mz
– POIL (female) (3) and ground tance
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)
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37
Failure code [B@BAZK] Lowering of engine oil 1

Action code Failure code Lowering of engine oil
Trouble
E01 B@BAZK (Retarder controller system)
Contents of
• Engine oil level switch circuit has become "OPEN" (disconnected with GND).
trouble
Action of
• Turns 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
38 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 39
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)
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41
Failure code [B@BCZK] Coolant level low alarm 1

Action code Failure code Coolant level low alarm
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
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
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.

and standard Lack of fuel (When system is
1 Fuel may be insufficient. Check and add fuel, if necessary.
value in normal normal)
state 2 Carry out troubleshooting for failure code [DJF1KA], if fuel is sufficient.
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 45
Failure code [B@C7NS] Overheating of brake cooling oil (Rear) 1

Action code Failure code Overheating of brake cooling oil (Rear)
Trouble
E02 B@C7NS (Machine monitor system)
Contents of • While engine was running, oil overheat was detected by signal from brake (retarder) (rear) oil tem-
trouble perature sensor.
Action of
• Displays brake oil temperature caution lamp red.
controller
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.

1) Remove relay cover.
2) Turn starting switch ON (Do not start engine).
1 Defective R14 (BCV relay) 3) Turn retarder brake ON and OFF and carry out troubleshooting.
R14 (BCV relay) Operating sound of relay is heard.
a Turn starting switch OFF and disconnect D12, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
2 Defective diode Forward direction:
Between D12 (male) There is continuity
Continuity
(1) – (2) Backward direction:
There is not continuity
1) Open operator's cab door.
2) Turn starting switch ON (Do not start engine).
3 Defective BCV solenoid 3) Turn retarder brake ON and OFF and carry out troubleshooting.
Operating sound of BCV sole-
BCV solenoid
Possible causes noid is heard.
and standard a Turn starting switch OFF and disconnect R14 (BCV relay) and
value in normal BCVR, then carry out troubleshooting without turning starting
state switch ON.
Disconnection in wiring har- Between R14 (female) (3) – BCVR (female) Resis-
ness (Disconnection in wiring (1) Max. 1 z
4 tance
or defective contact in con-
Resis-
nector) Between T05 (ground) – BCVR (female) (2) Max. 1 z
tance
Resis-
Between R14 (female) (5) – BT3 (12) Max. 1 z
tance
a Turn starting switch OFF and disconnect BCVR, then carry out
Grounding fault in wiring har- troubleshooting without turning starting switch ON.
5 ness (Contact with ground
circuit) Resis-
Between R14 (female) (1) and ground Min. 1 Mz
tance
Trouble in hydraulic system
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
normal)
If causes 1 – 6 are not detected, retarder controller may be defec-
7 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 47
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))

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].
48 HD465-7E0, HD605-7E0
Failure code [B@GAZK] Lowering of battery electrolyte level 1

Action code Failure code Lowering of battery electrolyte 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 BTC2 (female) (38) and BTL
harness (female).
3
(Disconnection in wiring or
defective contact in connector) Max. 1 z
(38) – BTL (female) (1) tance
2) Connect T-adapter to connector BTC2 (female).
4 Defective pump controller 3) Turn starting switch ON.
Between BRC2 (female) (38) – ground Voltage 20 – 30 V
HD465-7E0, HD605-7E0 49
Failure code [B@JANS] Overheating of steering oil 1

Action code Failure code Overheating of steering oil
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
• Turns 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 is overheated.
Possible causes Since the overheat of the steering oil can be suspected, if there is
1 (When the system is operat-
and standard an overheat, repair the cause of the failure.
ing normally)
value in normal
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].
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 51

© 2008 KOMATSU
All Rights Reserved
52 HD465-7E0, HD605-7E0
SEN01664-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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 ............................................................................................ 15
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
HD465-7E0, HD605-7E0 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 system disconnection or short circuit........................................................ 54
Failure code [CA342] Engine controller data 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 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) Between wiring harness 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
• Stops 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
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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) signal 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
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

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-
Between wiring harness ENG (female) (37) – Resis-
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 HD465-7E0, HD605-7E0

Between wiring harness ENG (female) (37) –
Resis-
PIM (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring (female) (47) – PIM (female) (3)
5 harness Between wiring harness ENG (female) (37) –
(with another wiring harness) PIM (female) (1) and wiring harness ENG Resis-
Min. 1 Mz
tance
Possible causes (female) (44) – PIM (female) (2)
and standard Between wiring harness ENG (female) (47) –
Resis-
value in normal PIM (female) (3) and wiring harness 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)
HD465-7E0, HD605-7E0 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) signal 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Between wiring harness J2P (female) (22) – Resis-
Grounding fault in wiring har- AS1 (female) (1) and ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Between wiring harness J2P (female) (9) – Resis-
Min. 1 Mz
AS1 (female) (2) and ground tance
Min. 1 Mz
12 HD465-7E0, HD605-7E0

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

HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10199
HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10206
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
HD465-7E0, HD605-7E0 13

Fig. 1

and switch 2
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

Resis-
POIL (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
5 ness Between wiring harness ENG (female) (37) –
(with another wiring harness) POIL (female) (1) and wiring harness ENG Resis-
Min. 1 Mz
tance
Possible causes (female) (13) – POIL (female) (3)
and standard Between wiring harness ENG (female) (47) –
Resis-
value in normal POIL (female) (2) and wiring harness 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)
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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-
– TWTR (female) (B) tance
state
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Between wiring harness ENG (female) (15) – Resis-
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 (50.99 kPa {0.52 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 HD465-7E0, HD605-7E0

Resis-
PAMB (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – PAMB (female) (3)
(with another wiring harness) PAMB (female) (1) and wiring harness ENG Resis-
Possible causes Min. 1 Mz
tance
and standard (female) (3) – PAMB (female) (2)
value in normal Between wiring harness ENG (female) (38) –
Resis-
state PAMB (female) (3) and wiring harness 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
HD465-7E0, HD605-7E0 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 (50.99 kPa {0.52 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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.
• Atmospheric pressure sensor sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and
Action of
continues operation.
controller
• Charge pressure sensor (boost 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

1 Related system defects If another code is displayed, carry out troubleshooting for it first.
Bkup speed sensor
G connector
system
Oil pressure sensor POIL connector
Disconnect device
Defective sensor suggested on the Charge pressure
2 PIM connector
(Internal defect) right. At this time, if sensor
failure code is not Atmospheric
indicated, the device PAMB connector
Possible causes pressure sensor
and standard is defective.
EGR valve lift sensor SEGR connector
value in normal
Bypass valve position
state SBP connector
sensor
3 Max. 1 z
(Disconnection or defective – each sensor (female) (+5 V) tance
contact of connector) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
– each sensor (female) (GND) tance
4 ness
Min. 1 Mz
each sensor (female) and ground tance
36 HD465-7E0, HD605-7E0

Short circuit in wiring har- without turning starting switch ON.
Possible causes (with another wiring harness) each sensor (female) and wiring harness Resis-
Min. 1 Mz
and standard tance
ENG (female) (47) – each sensor (female)
value in normal
6 Defective engine controller 3) Turn starting switch ON.
ENG (male) Voltage
Between (37) and (47) 4.75 – 5.25V
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
(Internal defect) right. At this time, if
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 wiring harness 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 normally, pulse voltage of about 24 V is applied to PCV1 (1) but it cannot be
information
measured with circuit tester since it is a pulse voltage.

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 Between wiring harness 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 Between wiring harness ENG (female) (4) –
(Contact with 24 V circuit) Voltage Max. 1 V
PCV1 (female) (1) and ground
Voltage Max. 1 V
4 Defective engine controller ENG (female) Resistance
Between (4) and (5) 2.3 – 5.3 z
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Between (4), (5) ground Min. 1 Mz
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 Between wiring harness 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 Between wiring harness ENG (female) (9) –
(Contact with 24 V circuit) Voltage Max. 1 V
Voltage Max. 1 V
Between (9) and (10) 2.3 – 5.3 z
Between (9), (10) ground Min. 1 Mz
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Between (9) and (10) 2.3 – 5.3 z
52 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 53
Failure code [CA322] Injector #1 system disconnection or short circuit 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 normally, pulse voltage of about 65 V is applied to injector (+) side but it can-
information
not be measured with circuit tester since it is a pulse voltage.

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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 65
Failure code [CA342] Engine controller data 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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
Max. 1 z
Possible causes – PFUEL (female) (3) tance
and standard Wiring harness between ENG (female) (48) Resis-
Max. 1 z
value in normal – NE (female) (2) tance
state a Prepare with starting switch OFF, then carry out troubleshooting
Min. 1 Mz
PFUEL (female) (1) and ground tance
4 ness Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Between wiring harnesses ENG (female)
Short circuit in wiring har- Resis-
(25) – PFUEL (female) (2) and ENG (female) Min. 1 Mz
5 ness tance
(except 25) – each sensor (female)
(with another wiring harness)
Resis-
(27) – NE (female) (3) and ENG (female) Min. 1 Mz
tance
(except 27)
68 HD465-7E0, HD605-7E0

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)
HD465-7E0, HD605-7E0 69

© 2009 KOMATSU
All Rights Reserved
70 HD465-7E0, HD605-7E0
SEN01665-04
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
Failure code [CA431] Idle validation switch error............................................................................................ 4
Failure code [CA432] Idle validation action error ............................................................................................ 8
Failure code [CA441] Battery voltage low error .............................................................................................. 8
Failure code [CA442] Battery voltage high error ............................................................................................. 9
Failure code [CA449] Common rail pressure high error 2 .............................................................................. 9
Failure code [CA451] Common rail pressure sensor high error.................................................................... 10
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 12
Failure code [CA553] Common rail pressure high error 1 ............................................................................ 13
Failure code [CA554] Common rail pressure sensor: In-range error ............................................................ 14
Failure code [CA559] Supply pump no-pressure feed error 1 ...................................................................... 15
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 18
Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 20
Failure code [CA757] All engine controller data lost error ............................................................................ 21
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 22
Failure code [CA1228] EGR valve servo error 1........................................................................................... 24
Failure code [CA1625] EGR valve servo error 2........................................................................................... 25
HD465-7E0, HD605-7E0 1
Failure code [CA1626] Short circuit in bypass valve solenoid drive system ................................................. 26
Failure code [CA1627] Disconnection in bypass valve solenoid drive system.............................................. 28
Failure code [CA1628] Bypass valve servo error 1....................................................................................... 29
Failure code [CA1629] Bypass valve servo error 2....................................................................................... 30
Failure code [CA1631] Bypass valve lift sensor high error ........................................................................... 32
Failure code [CA1632] Bypass valve lift sensor low error ............................................................................. 34
Failure code [CA1633] KOMNET (datalink timeout) error ............................................................................. 35
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 36
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 38
Failure code [CA2249] Supply pump no-pressure feed error 2..................................................................... 39
Failure code [CA2271] EGR valve lift sensor high error ............................................................................... 40
Failure code [CA2272] EGR valve lift sensor low error ................................................................................. 42
Failure code [CA2351] Short circuit in EGR valve solenoid drive system..................................................... 44
Failure code [CA2352] Disconnection in EGR valve solenoid drive system ................................................. 46
Failure code [CA2555] Intake heater relay voltage low error ........................................................................ 47
Failure code [CA2556] Intake heater relay voltage high error....................................................................... 48
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3
Failure code [CA431] Idle validation switch error 1

Action code Failure code Idle validation switch error
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
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
Related tion (Monitoring code: ENGINE 18300 (1: ON / 0: OFF)).
information • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring func-
tion (Monitoring code: ENGINE 18301 (1: ON / 0: OFF)).
HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10199
HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10206
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
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
Possible causes
and standard Wiring harness between J2P (female) (1) – Resis-
Max. 1 z
value in normal AS1 (female) (6) tance
state a Prepare with starting switch OFF, then carry out troubleshoot-
Grounding fault in wiring Min. 1 Mz
3 harness (Short circuit with
ground circuit) Between wiring harness J2P (female) (11) – Resis-
Min. 1 Mz
Min. 1 Mz
Between wiring harness J2P (female) (32) –
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4) and ground
4
24V circuit) in wiring harness Between wiring harness J2P (female) (11) –
Voltage Max. 1 V
AS1 (female) (5) and ground
Voltage Max. 1 V
4 HD465-7E0, HD605-7E0

Possible causes
and standard and carry out troubleshooting.
value in normal 5 Defective engine controller J2P Signal name Voltage
state
Between (11) – (32) Signal 1
See Fig. 1
Fig. 1

and switch 2
HD465-7E0, HD605-7E0 5

AS1 Signal name Voltage
Defective accelerator pedal See Fig. 1
1 Between (6) – (4) Signal 2
(Internal defect)
Between AS2 (1) – (2) Voltage 5V
Max. 1 z
Max. 1 z
ness (Disconnection in wiring AS1 (female) (5) tance
2
or defective contact in con- Wiring harness between J2P (female) (1) – Resis-
nector) Max. 1 z
Max. 1 z
– AS2 (female) (2) tance
Max. 1 z
– AS2 (female) (1) tance
Possible causes
and standard
value in normal Between wiring harness J2P (female) (32) – Resis-
Ground fault in wiring har- Min. 1 Mz
state AS1 (female) (4) and ground tance
3 ness (Short circuit with GND
circuit) Between wiring harness J2P (female) (11) – Resis-
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4) and ground
4
24V circuit) in wiring harness Between wiring harness J2P (female) (11) –
Voltage Max. 1 V
Voltage Max. 1 V
5 Defective engine controller J2P Signal name Voltage
See Fig. 1
1) Starting switch OFF.
2) Disconnect AS2.
Defective transmission con- 3) Disconnect ATC3 and ATC1.
6 4) Connect T-blanch to ATC3 and ATC1.
troller
5) Turn starting switch ON and carry out troubleshooting.
Between ATC3 (34) and ATC1 (4) Voltage 5V
6 HD465-7E0, HD605-7E0
Fig. 1

and switch 2
HD465-7E0, HD605-7E0 7
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
tion (Code: 18300).
Related
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
8 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 9
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
– PFUEL (female) (1) tance
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
– PFUEL (female) (3) tance
ness Between wiring harness ENG (female) (33) – Resis-
4 Min. 1 Mz
(Short circuit with ground PFUEL (female) (1) and ground tance
circuit) Between wiring harness ENG (female) (25) – Resis-
Min. 1 Mz
10 HD465-7E0, HD605-7E0

Resis-
PFUEL (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (25) – PFUEL (female) (2)
(with another wiring harness) PFUEL (female) (1) and wiring harness ENG Resis-
tance
and standard (female) (47) – PFUEL (female) (3)
value in normal Between wiring harness ENG (female) (25) –
Resis-
state PFUEL (female) (2) and wiring harness 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
HD465-7E0, HD605-7E0 11
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
12 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 13
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
14 HD465-7E0, HD605-7E0
Failure code [CA559] Supply pump no-pressure feed error 1 1

Action code Failure code Supply pump no-pressure feed error 1
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

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.
HD465-7E0, HD605-7E0 15
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) 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.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
16 HD465-7E0, HD605-7E0
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 Speed:
cc/min 960
1,600 rpm
Rating or equivalent
cc/min 1,020
1,700 rpm
12 Return rate from injector cc/min 1,080 Return rate:
1,800 rpm
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
HD465-7E0, HD605-7E0 17
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
– NE (female) (1) tance
Max. 1 z
tor) – NE (female) (2) tance
Max. 1 z
– NE (female) (3) tance
Grounding fault in wiring har- Between wiring harness ENG (female) (16) – Resis-
Min. 1 Mz
ness NE (female) (1) and ground tance
3
(Short circuit with ground Between wiring harness ENG (female) (48) – Resis-
Possible causes circuit) Min. 1 Mz
and standard
value in normal Min. 1 Mz
state
Resis-
NE (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
(with another wiring harness) NE (female) (1) and wiring harness ENG Resis-
Min. 1 Mz
tance
Resis-
NE (female) (2) and wiring harness 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 – 4 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.)
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19
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].
20 HD465-7E0, HD605-7E0
Failure code [CA757] All engine controller data lost error 1

Action code Failure code All engine controller 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
HD465-7E0, HD605-7E0 21
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
ness Between wiring harness ENG (female) (37) – Resis-
3 Min. 1 Mz
(Short circuit with ground G (female) (A) and ground tance
Possible causes circuit) Between wiring harness ENG (female) (26) – Resis-
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 wiring harness ENG Min. 1 Mz
5 ness tance
(female) (47) – G (female) (B)
(with another wiring harness)
Resis-
G (female) (B) and wiring harness ENG Min. 1 Mz
tance
(female) (26) – G (female) (C)
If causes 1 – 5 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.)
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Failure code [CA1228] EGR valve servo error 1 1

Action code Failure code EGR valve servo error 1
Trouble
Contents of • There is servo error (level 1) of EGR valve.
trouble (Position indicated for EGR valve is different from response of EGR lift sensor.)
Action of
• Performs open control.
controller
Problem that
appears on
machine
Related
information

a For measurement of EGR valve drive pressure, see Testing and
adjusting, “Testing EGR valve and bypass valve drive oil pres-
sure”.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Possible causes Defective engine oil pressure
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
and standard system (main circuit)
value in normal
state If engine oil pressure is not normal, carry out troubleshooting (S-
mode) for mechanical system. (S-12 Oil pressure lowers.)
Defective EGR valve oil Oil pump or relief valve for EGR valve circuit may be defective.
4
pump Check it directly.
Defective EGR valve oil Oil pressure supply piping for EGR valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
Defective EGR valve lift
sensor
24 HD465-7E0, HD605-7E0
Failure code [CA1625] EGR valve servo error 2 1

Action code Failure code EGR valve servo error 2
Trouble
Contents of • EGR valve servo trouble (level 2) occurred.
trouble (Position indicated for EGR valve is different from response of EGR lift sensor.)
controller • Close EGR and bypass valves.
Problem that
machine
Related
information

and standard
state
HD465-7E0, HD605-7E0 25
Failure code [CA1626] Short circuit in bypass valve solenoid drive

system 1
Action code Failure code Short circuit in bypass valve solenoid drive system
Trouble
Contents of
• High current was detected in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

Defective bypass valve sole- without turning starting switch ON.
1
noid (Internal defect) BP (male) Resistance
Between (1) and (2) 10 – 21 z
ness
2 (Disconnection in wiring or Max. 1 z
– BP (female) (1) tance
defective contact in connec-
tor) Wiring harness between ENG (female) (11) – Resis-
Max. 1 z
BP (female) (2) tance
Possible causes without turning starting switch ON.
and standard Grounding fault in wiring har-
value in normal ness Between wiring harness ENG (female) (31) – Resis-
3 Min. 1 Mz
state (Short circuit with ground BP (female) (1) and ground tance
circuit) Between wiring harness ENG (female) (11) – Resis-
Min. 1 Mz
BP (female) (2) and ground tance
Hot short in wiring harness Between wiring harness ENG (female) (31) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) BP (female) (1) and ground
Voltage Max. 1 V
BP (female) (2) and ground
ENG (female) Resistance
Between (31) and (11) 10 – 21 z
26 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 27
Failure code [CA1627] Disconnection in bypass valve solenoid drive

system 1
Action code Failure code Disconnection in bypass valve solenoid drive system
Trouble
Contents of
• Disconnection error was detected in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
28 HD465-7E0, HD605-7E0
Failure code [CA1628] Bypass valve servo error 1 1

Action code Failure code Bypass valve servo error 1
Trouble
Contents of • Bypass valve servo trouble (level 1) occurred.
trouble (Position indicated for bypass valve is different from response of bypass valve lift sensor.)
Action of
• Performs open control.
controller
Problem that
appears on
machine
Related
information

a For measurement of bypass valve drive pressure, see Testing
and adjusting, “Testing EGR valve and bypass valve drive oil
pressure”.
Improper bypass valve drive Engine speed Bypass valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
If bybass valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Possible causes Defective engine oil pressure
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
and standard system (main circuit)
value in normal
state If engine oil pressure is not normal, carry out troubleshooting (S-
mode) for mechanical system. (S-12 Oil pressure drops)
Defective bypass valve oil Oil pump or relief valve for bypass valve circuit may be defective.
4
pump Check it directly.
Defective bypass valve oil Oil pressure supply piping for bypass valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective bypass valve oil Oil pressure return piping for bypass valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective bypass valve Bypass valve may be damaged mechanically. Check it directly.
Defective bypass valve lift
sensor
HD465-7E0, HD605-7E0 29
Failure code [CA1629] Bypass valve servo error 2 1

Action code Failure code Bypass valve servo error 2
Trouble
Contents of
• There is servo error (level 2) of bypass valve.
trouble
Problem that
machine
Related
information

and standard
state
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
Failure code [CA1631] Bypass valve lift sensor high error 1

Action code Failure code Bypass valve lift sensor high error
Trouble
Contents of
• Bypass valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200 (mm)).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202 (V)).
• Method of reproducing failure code: Start engine

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
SBP Voltage
Defective bypass valve lift
2 Between (1) and (2) Power supply 4.75 – 5.25 V
sensor (Internal defect)
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal ness Max. 1 z
– SBP (female) (1) tance
state 3 (Disconnection in wiring or
Max. 1 z
tor) – SBP (female) (2) tance
Max. 1 z
– SBP (female) (3), (4) tance
Grounding fault in wiring har- Between wiring harness ENG (female) (37) – Resis-
Min. 1 Mz
ness SBP (female) (1) and ground tance
4
(Short circuit with ground Between wiring harness ENG (female) (38) – Resis-
circuit) Min. 1 Mz
SBP (female) (2) and ground tance
Min. 1 Mz
SBP (female) (3), (4) and ground tance
32 HD465-7E0, HD605-7E0

Resis-
SBP (female) (1) and wiring harness ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – SBP (female) (2)
Possible causes 5 ness Between wiring harness ENG (female) (37) –
(with another wiring harness) SBP (female) (1) and wiring harness ENG Resis-
tance
value in normal (female) (29) – SBP (female) (3), (4)
state Between wiring harness ENG (female) (38) –
Resis-
SBP (female) (2) and wiring harness ENG Min. 1 Mz
tance
(female) (29) – SBP (female) (3), (4)
ENG Voltage
Between (37) and (38) 4.75 – 5.25 V
HD465-7E0, HD605-7E0 33
Failure code [CA1632] Bypass valve lift sensor low error 1

Action code Failure code Bypass valve lift sensor low error
Trouble
Contents of
• Bypass valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202 (V)).
• Method of reproducing failure code: Start engine

and standard
state
34 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 35
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 Between wiring harness J2P (female) (22) –
(with another wiring harness) AS1 (female) (1) and wiring harness J2P Resis-
Min. 1 Mz
tance
(female) (23) – AS1 (female) (3)
J2P Voltage
Between (22) and (23) 4.75 – 5.25 V
36 HD465-7E0, HD605-7E0

HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10199
HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10206

HD465-7E0, HD605-7E0 37
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
38 HD465-7E0, HD605-7E0
Failure code [CA2249] Supply pump no-pressure feed error 2 1

Action code Failure code Supply pump no-pressure feed 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
HD465-7E0, HD605-7E0 39
Failure code [CA2271] EGR valve lift sensor high error 1

Action code Failure code EGR valve lift sensor high error
Trouble
Contents of
• EGR valve lift sensor circuit is abnormally high.
trouble
controller • Closes EGR valve.
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 (V)).

Defective sensor power sup- If failure code [CA187] or [CA227] is also indicated, carry out trou-
1
ply system bleshooting for it first.
SEGR Voltage
Defective EGR valve lift sen-
2 Between (1) and (2) Power supply 4.75 – 5.25 V
sor (Internal defect)
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
ness – SEGR (female) (1) tance
state 3
– SEGR (female) (2) tance
Max. 1 z
– SEGR (female) (3), (4) tance
Grounding fault in wiring har- SEGR (female) (1) and ground Min. 1 Mz
tance
4 ness
Min. 1 Mz
SEGR (female) (2) and ground tance
Min. 1 Mz
SEGR (female) (3), (4) and ground tance
40 HD465-7E0, HD605-7E0

Resis-
(37) – SEGR (female) (1) and ENG (female) Min. 1 Mz
tance
Short circuit in wiring har- (47) – SEGR (female) (2)
Possible causes 5 ness Between wiring harnesses ENG (female)
(with another wiring harness) (37) – SEGR (female) (1) and ENG (female) Resis-
tance
value in normal (19) – SEGR (female) (3), (4)
state Between wiring harnesses ENG (female)
Resis-
(47) – SEGR (female) (2) and ENG (female) Min. 1 Mz
tance
(19) – SEGR (female) (3), (4)
ENG Voltage
Between (37) and (47) 4.75 – 5.25 V
HD465-7E0, HD605-7E0 41
Failure code [CA2272] EGR valve lift sensor low error 1

Action code Failure code EGR valve lift sensor low error
Trouble
Contents of
• EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 (V)).

and standard
state
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
Failure code [CA2351] Short circuit in EGR valve solenoid drive

system 1
Action code Failure code Short circuit in EGR valve solenoid drive system
Trouble
Contents of
• High current was detected in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

Defective EGR valve sole- without turning starting switch ON.
1
noid (Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 z
2 Max. 1 z
(Disconnection or defective – EGR (female) (1) tance
contact of connector) Wiring harness between ENG (female) (11) – Resis-
Max. 1 z
EGR (female) (2) tance
and standard Grounding fault in wiring har-
value in normal Between wiring harness ENG (female) (22) – Resis-
3 ness Min. 1 Mz
state EGR (female) (1) and ground tance
Min. 1 Mz
EGR (female) (2) and ground tance
Hot short in wiring harness Between wiring harness ENG (female) (22) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) EGR (female) (1) and ground
Voltage Max. 1 V
EGR (female) (2) and ground
ENG (female) Resistance
Between (22) and (11) 10 – 21z
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 45
Failure code [CA2352] Disconnection in EGR valve solenoid drive

system 1
Action code Failure code Disconnection in EGR valve solenoid drive system
Trouble
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
46 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 47
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
Min. 1 Mz
4 Defective engine controller J2P Heater relay Voltage
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 49

© 2009 KOMATSU
All Rights Reserved
50 HD465-7E0, HD605-7E0
SEN01666-04
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
40 Troubleshooting
Failure code [D19HKB] Short circuit in stop lamp relay output system........................................................... 3
Failure code [D5ZKKZ] Trouble in front brake cut valve system (Disconnection or short circuit) ................... 4
Failure code [DAF9KM] Wrong connection of connector ................................................................................ 6
Failure code [DAFRKR] Abnormal CAN communication (machine monitor) .................................................. 8
Failure code [DAQ0KK] Lowering of power supply voltage in transmission controller
direct power supply................................................................................................................................ 10
Failure code [DAQ0KT] Abnormality in transmission controller nonvolatile memory .................................... 12
Failure code [DAQ2KK] Transmission controller solenoid power supply voltage low error .......................... 13
Failure code [DAQ9KQ] Disagreement of model selection signal (Transmission controller) ........................ 14
Failure code [DAQRKR] Abnormality in CAN communication (Transmission controller).............................. 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ..................................... 15
Failure code [DB10KT] Abnormality in retarder controller nonvolatile memory ............................................ 15
Failure code [DB12KK] Trouble in retarder controller solenoid power supply system .................................. 16
Failure code [DB13KK] Retarder controller battery direct power supply voltage low error ........................... 18
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 20
Failure code [DB1RKR] Abnormality in CAN communication (Retarder controller) ...................................... 22
HD465-7E0, HD605-7E0 1
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) ............................................. 24

Failure code [DB2RKR] Abnormality in CAN communication (Engine controller)......................................... 26
VHMS controller: Low source voltage (input)......................................................................................... 30
(VHMS controller: Disagreement of model selection signals)................................................................ 32
VHMS controller battery power supply: Low source voltage (input) ...................................................... 33
(VHMS controller 5 V power supply output: Low output voltage)........................................................... 36
(VHMS controller 24 V power supply output: Low output voltage)......................................................... 38
(VHMS controller 12 V power supply output: Low output voltage)......................................................... 40
(Abnormality in target component system) ............................................................................................ 42
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ......................................................... 45
Failure code [DBC2KK] Trouble in ABS controller solenoid power supply system ....................................... 46
Failure code [DBC3KK] ABS controller battery direct power supply voltage low error ................................. 48
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)................................................. 50
Failure code [DBCRKR] Abnormality in CAN communication (ABS controller) ............................................ 50
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................................... 51
Failure code [DDD7KX] Trouble in travel speed setting switch system
(If equipped) (When ARSC is set and ARSC system switch is ON) ...................................................... 52
Failure code [DDD8KA] Disconnection in ARSC system switch
Failure code [DDD8KB] Short circuit in ARSC system switch
Failure code [DDD9KA] Disconnection in ABS system switch
(When ABS is set and ABS system switch is ON) ................................................................................. 58
Failure code [DDD9KB] Short circuit in ABS system switch
(When ABS is set and ABS system switch is ON) ................................................................................. 60
Failure code [DDDAKA] Disconnection in ASR system switch ..................................................................... 62
Failure code [DDDAKB] Short circuit in ASR system switch......................................................................... 64
Failure code [DDP6L4] Trouble in service brake pressure switch (Rear) ..................................................... 66
Failure code [DDTHKA] Trouble in Hi clutch fill switch
(Command is holding pressure, fill switch is OFF, and slip is not sensed) ............................................ 68
Failure code [DDTJKA] Trouble in Lo clutch fill switch
Failure code [DDTKKA] Trouble in 1st clutch fill switch
Failure code [DDTLKA] Trouble in 2nd clutch fill switch
Failure code [DDTMKA] Trouble in 3rd clutch fill switch
Failure code [DDTNKA] Trouble in R clutch fill switch
Failure code [DDTPKA] Trouble in 4th clutch fill switch
Failure code [DF10KA] Gear shift lever signal non-input .............................................................................. 82
Failure code [DF10KB] Gear shift lever signal multi-input ............................................................................ 85
(Atmospheric temperature sensor: Out of input signal range) ............................................................... 88
Failure code [DGF1KX] Transmission oil temperature sensor input signal out of range............................... 90
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor rear wheel system (Ground fault) ........ 92
Failure code [DGR6KX] Steering oil temperature sensor input signal out of range ...................................... 94
Failure code [DGT1KX] Torque converter oil temperature sensor input signal out of range......................... 96
2 HD465-7E0, HD605-7E0
Failure code [D19HKB] Short circuit in stop lamp relay output system 1
Action code Failure code Short circuit in stop lamp relay output system
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) Between wiring harness BRC2 (female) (18) Resis-
Min. 1 Mz
– 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
HD465-7E0, HD605-7E0 3
Failure code [D5ZKKZ] Trouble in front brake cut valve system

(Disconnection or short circuit) 1
Action code Failure code Trouble in front brake cut valve system (Disconnection or short cir-
Trouble cuit)
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
1 S03 (male) Resistance
solenoid valve
Between (1) – (2) 20 – 40 z
(1), (2) – ground Min. 1 Mz
Disconnection in wiring har- 2) Connect T-adapter to connector 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- Between wiring harness BRC3 (female) (28) Resis-
Min. 1 Mz
value in normal 3 ness – 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
circuit) in wiring harness 4) Turn front brake cut switch OFF.
Between wiring harness BRC3 (female) (28)
Voltage Max. 1 V
– S03 (female) (1) and ground
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Between DPC3A (female) (5) – pin other Resis-
harness) Min. 1 Mz
than DPC3A (5) tance
4 Defective machine monitor Check by replacing machine monitor.
6 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 7
Failure code [DAFRKR] Abnormal CAN communication (machine

monitor) 1
Action code Failure code Abnormal CAN communication (machine monitor)
Trouble
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- 120 ± 12
resistance
side) tance z
Resis- 120 ± 12
Between CAN2 (male) (A) – (B) (Inner cab)
tance z
Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
(8) – CAN2 (female) (A), (B) tance
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Max. 1 z
(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-
Possible causes contact) Max. 1 z
(8) – DL (male) (3), (10) tance
and standard
state (8) – CAN2 (female) (A), (B) tance
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 Min. 1 Mz
3 DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
DPC4 (female) (3) – ATC2 (female) (32) tance
Min. 1 Mz
DPC4 (female) (3) – J2P (female) (46) tance
Min. 1 Mz
8 HD465-7E0, HD605-7E0

Min. 1 Mz
DPC4 (female) (3) – DL (male) (3) tance
Max. 1 z
Short circuit of harness DPC4 (female) (3) – HM-CN4A (female) (4) tance
3 (Contact with ground circuit) Between ground and wiring harness between Resis-
DPC4 (female) (3) – ABS2 (female) (32) tance
and standard
Between ground and wiring harness between
value in normal 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
HD465-7E0, HD605-7E0 9
Failure code [DAQ0KK] Lowering of power supply voltage in

transmission controller direct power supply 1
Action code Failure code Lowering of power supply voltage in transmission controller direct
Trouble power supply
E03 DAQ0KK (Transmission controller system)
Contents of • While engine was running, transmission controller direct power supply circuit voltage lowered below
trouble 18 V.
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 If there is voltage between battery relay terminal B and ground and
and standard 2
(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 3) Connect negative (–) terminal of battery.
troller
Between ATC3 (1), (11) – (21), (31), (32),
Voltage 20 – 30 V
(33)
10 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 11
Failure code [DAQ0KT] Abnormality in transmission controller

nonvolatile memory 1
Action code Failure code Abnormality in transmission controller nonvolatile memory
Trouble
E01 DAQ0KT (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 1 (It is no problem to keep using controller unless any visible trouble
controller
state symptom appears on machine.)
12 HD465-7E0, HD605-7E0
Failure code [DAQ2KK] Transmission controller solenoid power supply

voltage low error 1
Action code Failure code Transmission controller solenoid power supply voltage low error
Trouble
E03 DAQ2KK (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.
Disconnection in wiring 3) Connect negative (–) terminal of battery.
harness 4) Turn starting switch ON.
1
(Disconnection or defective 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)
HD465-7E0, HD605-7E0 13
Failure code [DAQ9KQ] Disagreement of model selection signal

(Transmission controller) 1
Action code Failure code Disagreement of model selection signal (Transmission controller)
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

(Transmission controller) 1
Action code Failure code Abnormality in CAN communication (Transmission controller)
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 HD465-7E0, HD605-7E0
Failure code [DAQRMA] Disagreement of option setting (Transmission

controller) 1
Action code Failure code Disagreement of option setting (Transmission controller)
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
Defective option setting of machine monitor or internal defect of
value in normal 1 Defective machine monitor
monitor
state
Failure code [DB10KT] Abnormality in retarder controller nonvolatile

memory 1
Action code Failure code Abnormality in retarder controller nonvolatile memory
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
Since this is an internal defect, it cannot be diagnosed.
value in normal 1 Defective retarder controller
Replace to controller.
state
HD465-7E0, HD605-7E0 15
Failure code [DB12KK] Trouble in retarder controller solenoid power

supply system 1
Action code Failure code Trouble in retarder controller solenoid power supply system
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 (female) (2), (12), (22) has disconnection.
contact)
value in normal 2) Disconnect negative (–) terminal of battery and connect T-
state adapter to BRC3 (female).
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
Failure code [DB13KK] Retarder controller battery direct power supply

voltage low error 1
Action code Failure code Retarder controller battery direct power supply voltage low error
Trouble
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
Possible causes Disconnection in wiring har- 2) Disconnect battery (–) terminal and insert T-adapter in BRC3
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 BRC3 (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
3 (female).
troller 3) Connect battery (–) terminal.
Between BRC3 (1), (11) – ground Voltage 20 – 30 V
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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.
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
Defective transmission con- Wrong reterder controller may be installed. Check its part No. and
2
troller install correct reterder controller.
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21
Failure code [DB1RKR] Abnormality in CAN communication (Retarder

controller) 1
Action code Failure code Abnormality in CAN communication (Retarder controller)
Trouble (Between retarder controller – transmission controller)
E03 DB1RKR (Transmission controller system)
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

resistance
side) tance z
Resis- 120 ± 12
tance z
Max. 1 z
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Max. 1 z
(8) – ATC2 (female) (32), (22) tance
Max. 1 z
harness (8) – J2P (female) (46), (47) tance
Possible causes 2
(Disconnection or defective Wiring harness between DPC4 (female) (3), Resis-
and standard contact) Max. 1 z
value in normal (8) – DL (male) (3), (10) tance
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
Resis-
tance
(female) (A), (B)
Min. 1 Mz
Short circuit of harness
3
(Contact with ground circuit) Between ground and wiring harness between Resis- Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
Min. 1 Mz
22 HD465-7E0, HD605-7E0

Min. 1 Mz
Min. 1 Mz
Short circuit of harness Between ground and wiring harness between Resis-
Max. 1 z
3 (Contact with ground circuit) DPC4 (female) (3) – HM-CN4A (female) (4) tance
DPC4 (female) (3), (8) – ABS2 (female) (32) tance
and standard
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
HD465-7E0, HD605-7E0 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.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
Failure code [DB2RKR] Abnormality in CAN communication (Engine

controller) 1
Action code Failure code Abnormality in CAN communication (Engine controller)
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).
resistance
side) tance z
Resis- 120 ± 12
tance z
Max. 1 z
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Max. 1 z
Disconnection in wiring (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) Wiring harness between DPC4 (female) (3), Resis-
state Max. 1 z
(8) – DL (male) (3), (10) tance
Max. 1 z
Max. 1 z
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 HD465-7E0, HD605-7E0

Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Max. 1 z
Short circuit of harness DPC4 (female) (3) – HM-CN4A (female) (4) tance
3
(Contact with ground circuit) Between ground and wiring harness between Resis-
Max. 1 z
Possible causes DPC4 (female) (3) – ABS2 (female) (32) tance
and standard Between ground and wiring harness between
Resis-
value in normal J2P (female) (46) – CAN2 (female) (A) – Min. 1 Mz
tance
state CAN2 (female) (A)
Resis-
J2P (female) (39) – BT3 (20) – (19) – starting Max. 1 z
tance
switch (terminal 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
HD465-7E0, HD605-7E0 27
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29
Failure code [DBB0KK] (or VHMS_LED display: “n9” o “01”) VHMS

controller: Low source voltage (input) 1
Action code Failure code VHMS controller: Low source voltage (input)
Trouble
— DBB0KK (VHMS controller system) (Display: PLM)
Contents of
• Voltage of VHMS controller switch fell to below 19.5 V while the engine speed is above 500 rpm.
trouble
Action of • None in particular.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “n9” o “01”.
• Method of reproducing failure code: Start engine and raise the engine speed above 500 rpm

Defective fuse No.(19), (20) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT1 (See cause 3.)
ness Wiring harness between fuse No.(19), (20) Resis-
2 Max. 1 z
(Disconnection or defective of fuse box BT1 – HM-CN1 (female) (8), (9) tance
contact) Wiring harness between HM-CN1 (female) Resis-
Possible Max. 1 z
(11), (12), (19), (20) and chassis ground tance
causes and
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between fuse No.(19), (20)
(Contact with ground circuit) of fuse box BT1 – HM-CN1 (female) (8), (9) Resis-
Min. 1 Mz
tance
and chassis ground
after starting engine and raising the engine speed above 500 rpm
Defective VHMS & PLM
4 HM-CN1 Voltage
controller
Between (8), (9) and (11), (12),
20 – 30 V
(19), (20) or chassis ground
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31

(VHMS controller: Disagreement of model selection signals) 1
Action code Failure code VHMS controller: Disagreement of model selection signals
Trouble
— DBB0KQ (VHMS controller system) (Display: PLM)
Contents of
• Improperly connected connectors were detected.
trouble
Problem that
appears on • The system may not work properly.
machine
information • The LED of the VHMS controller displays “nF” o “11”.

Possible Improperly connected con-
Check connection between HM-CN2A and HM-CN3A connectors,
causes and 1 nectors in VHMS controller
and HM-CN2B and HM-CN3B connectors for abnormality.
standard value (when the system is normal)
in normal state Defective VHMS & PLM If the above is normal, VHMS & PLM controller may be defective.
2
controller (Since trouble is in system, troubleshooting cannot be carried out.)
32 HD465-7E0, HD605-7E0

VHMS controller battery power supply: Low source voltage (input) 1
Action code Failure code VHMS controller: Low source voltage (input)
Trouble
— DBB3KK (VHMS controller system) (Display: PLM)
Contents of
• Constant voltage of VHMS controller fell to below 10 V.
trouble
Problem that
appears on —
machine
• Method of reproducing failure code: Keep the starting switch turned OFF

Defective fuse No.(29), (30) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT2 (See cause 3.)
ness Wiring harness between fuse No.(29), (30) Resis-
2 Max. 1 z
(Disconnection or defective of fuse box BT2 – HM-CN1 (female) (6), (7) tance
Possible Max. 1 z
(11), (12), (19), (20) and chassis ground tance
causes and
in normal state Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between fuse No.(29), (30)
(Contact with ground circuit) of fuse box BT2 – HM-CN1 (female) (6), (7) Resis-
Min. 1 Mz
tance
and chassis ground
4 HM-CN1 Voltage
controller
Between (6), (7) and (11), (12),
20 – 30 V
(19), (20) or chassis ground
HD465-7E0, HD605-7E0 33
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35

(VHMS controller 5 V power supply output: Low output voltage) 1
Action code Failure code VHMS controller 5 V power supply output: Low output voltage
Trouble
— DBB5KP (VHMS controller system) (Display: PLM)
Contents of
• VHMS controller 5 V sensor power supply is shorted with the chassis ground.
trouble
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on —
machine

Possible 1 ness Wiring harness between HM-CN1 (female)
(Contact with ground circuit) (4), (5) – HM12 (female) (B) and chassis Resis-
causes and Min. 1 Mz
tance
standard value ground
in normal state a Prepare with starting switch OFF, then turn starting switch ON
Defective VHMS & PLM and carry out troubleshooting
2
controller Between HM-CN1 (female) (4), (5) and HM-
Voltage 4.5 – 5.5 V
CN2A (female) (12) or chassis ground
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37

Trouble
Contents of • VHMS controller 24 V sensor and VHMS indicator lamp power supply is shorted with the chassis
trouble ground.
Problem that
appears on —
machine

1 ness Wiring harness between HM-CN1 (female)
Possible (Contact with ground circuit) (2) – HN25 (female) (2), – HM-21A (female) Resis-
Min. 1 Mz
causes and (1), – HM-21B (female) (1) and chassis tance
standard value ground
in normal state a Prepare with starting switch OFF, then turn starting switch ON
2 HM-CN1 Voltage
controller
Between (2) and (11), (12), (19),
20 – 30 V
(20) or chassis ground
38 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 39

Trouble
Contents of
• VHMS controller 12 V indicator lamp power supply is shorted with the chassis ground.
trouble
Problem that
appears on —
machine

1 ness
(Contact with ground circuit) Wiring harness between HM-CN1 (female)
Possible Resis-
Min. 1 Mz
causes and (3) – LM1 and chassis ground tance
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
2 HM-CN1 Voltage
controller
Between (3) and (11), (12), (19),
11.5 – 12.5 V
(20) or chassis ground
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41

(Abnormality in target component system) 1
Action code Failure code VHMS controller CAN communication: Defective communication
Trouble (Abnormality in target component system)
— DBBQKR (VHMS controller system) (Display: PLM)
Contents of
• CAN communication information from each controller cannot be received.
trouble
Action of
controller
Problem that
appears on • The system may not work properly.
machine
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n8” o “02”.
information • If failure code [CA1633], [DAFRKR], [DAQRMA] or [DB2RKR] is displayed, carry out troubleshoot-
ing for it first.

Wiring harness between HM-CN4A (female)
Disconnection in wiring har- (12) – ATC2 (female) (22), – BRC2 (female) Resis-
ness (22), – DL (female) (10), – DPC4 (female) Max. 1 z
1 tance
(8), – J2P (female) (47), – ABS2 (female)
(22)
contact of connector)
(4) – ATC2 (female) (32), – BRC2 (female) Resis-
Max. 1 z
(32), – DL (female) (3), – DPC4 (female) (3), tance
– J2P (female) (46), – ABS2 (female) (32)
(12) – ATC2 (female) (22), – BRC2 (female)
Possible Resis-
causes and Grounding fault in wiring har- (22), – DL (female) (10), – DPC4 (female) tance
Min. 1 Mz
(8), – J2P (female) (47), – ABS2 (female)
standard value 2 ness
(22) and chassis ground
in normal state (Contact with ground circuit)
(4) – ATC2 (female) (32), – BRC2 (female) Resis-
(32), – DL (female) (3), – DPC4 (female) (3), Min. 1 Mz
tance
and chassis ground
(22), – DL (female) (10), – DPC4 (female) Voltage Max. 1 V
Hot short in wiring harness (8), – J2P (female) (47), – ABS2 (female)
3
(Contact with 24 V circuit) (22) and chassis ground
(32), – DL (female) (3), – DPC4 (female) (3), Voltage Max. 1 V
and chassis ground
42 HD465-7E0, HD605-7E0

Defective CAN end point without turning starting switch ON.
4
Possible resistance CAN2 (male) (Two places) Resistance
causes and Between (A) and (B) 110 – 140 z
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
5 HM-CN4A Voltage
controller
Between (4), (12) and
4–8V
chassis ground
HD465-7E0, HD605-7E0 43
44 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 45
Failure code [DBC2KK] Trouble in ABS controller solenoid power

supply system 1
Action code Failure code Trouble in ABS controller solenoid power supply system
Trouble
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 (female) (2), (12), (22) has disconnection.
contact)
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
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 47
Failure code [DBC3KK] ABS controller battery direct power supply

voltage low error 1
Action code Failure code ABS controller battery direct power supply voltage low error
Trouble
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
and standard Disconnection in wiring har- 2) Disconnect battery (–) terminal and insert T-adapter in ABS3
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
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 49
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

controller) 1
Action code Failure code Abnormality in CAN communication (ABS controller)
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
50 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 51
Failure code [DDD7KX] Trouble in travel speed setting switch system (If
equipped) (When ARSC is set and ARSC system switch is ON) 1
Action code Failure code Trouble in travel speed setting switch system (If equipped)
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD7KX (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- 250 ± 25
Between RE3 (female) (1) – (2)
tance z
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
4 Wiring harness between BRC1 (female) Resis-
value in normal (Disconnection or defective Max. 1 z
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
Between BRC1 TOUCH UP tance z
(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
52 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 53
Failure code [DDD8KA] Disconnection in ARSC system switch (If

Action code Failure code Disconnection in ARSC system switch (If equipped)
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
1 3) Connect T-adapter.
Wiring harness between DPC2B (female) Resis-
contact) 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).
54 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 55
Failure code [DDD8KB] Short circuit in ARSC system switch (If

Action code Failure code Short circuit in ARSC system switch (If equipped)
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.
1 Hot short in wiring harness
Voltage Max. 1 V
DPC2B (female) (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.
ARSC system switch defec-
and standard 2 System switch is nor-
tive When the ARSC system switch No
value in normal 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).
56 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 57
Failure code [DDD9KA] Disconnection in ABS system switch (When

ABS is set and ABS system switch is ON) 1
Action code Failure code Disconnection in ABS system switch
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)
Max. 1 z
(8) – ABS (female) (2) tance
2) Replace the ABS system switch with normal one.
Possible causes
2 Defective ABS system switch System switch is nor-
and standard 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).
58 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 59
Failure code [DDD9KB] Short circuit in ABS system switch (When ABS
is set and ABS system switch is ON) 1
Action code Failure code Short circuit in ABS system switch
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.
controller
Problem that
machine
Related
information

2) Disconnect connectors ABS and DPC2B.
Disconnection in wiring har- 4) Turn the starting switch ON.
ness Between ground and wiring harness
1
(Disconnection or defective between DPC2B (female) (2) – ABS Voltage Max. 1 V
contact) (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).
60 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 61
Failure code [DDDAKA] Disconnection in ASR system switch 1

Action code Failure code Disconnection in ASR system switch
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.
controller
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-
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.
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
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"
62 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 63
Failure code [DDDAKB] Short circuit in ASR system switch 1

Action code Failure code Short circuit in ASR system switch
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.
controller
Problem that
• Machine is not affected particularly.
appears on
Related
information

2) Disconnect connectors ASR and DPC2B.
1 Hot short in wiring harness
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 3) Turn starting switch ON.
Defective ASR system
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"
64 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 65
Failure code [DDP6L4] Trouble in service brake pressure switch (Rear)1

Action code Failure code Trouble in service brake pressure switch (Rear)
Trouble
E03 DDP6L4 (Retarder controller system)
Contents of
• When foot brake is pressed, signal is not sent from service brake pressure switch.
trouble
Action of
controller
Problem that
appears on • When foot brake is pressed, brake lamp (rear center lamp) does not light up.
machine
Related
information

1) Remove relay cover.
Defective R08 (STOP LAMP 2) Turn starting switch ON (Do not start engine).
1
relay) 3) Turn foot brake ON and OFF to check relay.
R08 Turning ON/OFF sound is heard.
diode check mode).
Forward direction:
Between D09 (male) There is continuity
Continuity
(1) (-) – (2) (+) Backward direction:
2 Defective diode
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:
a Turn starting switch OFF and disconnect BRC1, S01 and
D10,then carry out troubleshooting without turning starting
switch ON.
Between S01 (female) (A) – D10 (female) Resis-
ness (Disconnection in wiring Max. 1 z
4 (1) tance
or defective contact in con-
Between BRC1 (female) (17) – D10 Resis-
nector) Max. 1 z
(female) (2) tance
Resis-
Between S01 (female) (B) – ground Max. 1 z
tance
66 HD465-7E0, HD605-7E0

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) and ground Min. 1 Mz
Possible causes circuit) tance
and standard Resis-
value in normal Between D10 (female) (2) and 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)
out.)
HD465-7E0, HD605-7E0 67
Failure code [DDTHKA] Trouble in Hi clutch fill switch (Command is

holding pressure, fill switch is OFF, and slip is not sensed) 1
Action code Failure code Trouble in Hi clutch fill switch
(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

2) Disconnect connector H.SW (CN20).
1 Defective Hi clutch fill switch When dis- Resis-
Min. 1 Mz
Between H.SW (CN20) (male) engaged tance
Max. 1 z
engaged tance
Disconnection in wiring har- 2) Disconnect connectors ATC3 and H.SW (CN20).
and standard
ness
value in normal 2 3) Connect T-adapter.
state Wiring harness between ATC3 (female) (30) Resis-
contact) Max. 1 z
– H.SW (CN20) (female) (1) tance
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
68 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 69
Failure code [DDTJKA] Trouble in Lo clutch fill switch (Command is

Action code Failure code Trouble in Lo clutch fill switch
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

2) Disconnect connector L.SW (CN18).
1 Defective Lo clutch fill switch When dis- Resis-
Min. 1 Mz
Between L.SW (CN18) (male) engaged tance
Max. 1 z
engaged tance
Disconnection in wiring har- 2) Disconnect connectors ATC3 and L.SW (CN18).
and standard
ness
contact) Max. 1 z
– L.SW (CN18) (female) (1) tance
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
70 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 71
Failure code [DDTKKA] Trouble in 1st clutch fill switch (Command is

Action code Failure code Trouble in 1st clutch fill switch
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
Between 1.SW (CN7) (male) (1) engaged tance
– ground When Resis-
Max. 1 z
engaged tance
Disconnection in wiring har- 2) Disconnect connectors ATC3 and 1.SW (CN7).
and standard
ness
contact) Max. 1 z
– 1.SW (CN7) (female) (1) tance
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
72 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 73
Failure code [DDTLKA] Trouble in 2nd clutch fill switch (Command is

Action code Failure code Trouble in 2nd clutch fill switch
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
Between 2.SW (CN9) (male) (1) engaged tance
– ground When Resis-
Max. 1 z
engaged tance
and standard Disconnection in wiring har- 2) Disconnect connectors ATC5 and 2.SW (CN9).
value in normal ness
contact) Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
74 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 75
Failure code [DDTMKA] Trouble in 3rd clutch fill switch (Command is

Action code Failure code Trouble in 3rd clutch fill switch
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
Max. 1 z
engaged tance
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and 3.SW (CN11).
value in normal ness
contact) Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
76 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 77
Failure code [DDTNKA] Trouble in R clutch fill switch (Command is

Action code Failure code Trouble in R clutch fill switch
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

2) Disconnect connector R.SW (CN13).
1 Defective R clutch fill switch When dis- Resis-
Min. 1 Mz
Between R.SW (CN13) (male) engaged tance
Max. 1 z
engaged tance
and standard 2) Disconnect connectors ATC3 and R.SW (CN13).
ness
contact) Max. 1 z
– R.SW (CN13) (female) (1) tance
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
78 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 79
Failure code [DDTPKA] Trouble in 4th clutch fill switch (Command is

Action code Failure code Trouble in 4th clutch fill switch
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
Max. 1 z
engaged tance
Disconnection in wiring har- 2) Disconnect connectors ATC3 and 4.SW (CN15).
and standard
ness
contact) Max. 1 z
3 When dis- Resis-
troller Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
80 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 81
Failure code [DF10KA] Gear shift lever signal non-input 1

Action code Failure code Gear shift lever signal non-input
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
82 HD465-7E0, HD605-7E0

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)
–ground In shift range other
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"
HD465-7E0, HD605-7E0 83

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"
84 HD465-7E0, HD605-7E0
Failure code [DF10KB] Gear shift lever signal multi-input 1

Action code Failure code Gear shift lever signal multi-input
Trouble
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
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 (a 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"
HD465-7E0, HD605-7E0 85

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"
86 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 87

(Atmospheric temperature sensor: Out of input signal range) 1
Action code Failure code Atmospheric temperature sensor: Out of input signal range
Trouble
— DGE5KX (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
trouble less.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the atmospheric temperature.
machine
information • The input state (temperature) from the atmospheric temperature sensor can be checked with the
monitoring function (Code: 37501 ATR TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Defective atmospheric tem- Atmospheric
perature sensor FL06 (male) Resistance
1 temperature
(Internal disconnection or
25°C (Normal temp) 3.6 – 4.7 kz
short circuit)
Between (A) and (B) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz
ness Wiring harness between HM-CN2A (female) Resis-
2 Max. 1 z
(Disconnection or defective (10) – FL06 (female) (A) tance
contact of connector) Wiring harness between FL06 (female) (B) – Resis-
Possible Max. 1 z
chassis ground tance
causes and
in normal state 3 ness
Wiring harness between HM-CN2A (female) Resis-
(Contact with ground circuit) Min. 1 Mz
(10) – FL06 (female) (A) and chassis ground tance
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between HM-CN2A (female)
Voltage Max. 1 V
(10) –FL06 (female) (A) and chassis ground
Atmospheric
Defective VHMS & PLM HM-CN2A (female) Resistance
5 temperature
controller
25°C (Normal temp) 3.6 – 4.7 kz
Between (10) and (12) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz
88 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 89
Failure code [DGF1KX] Transmission oil temperature sensor input

signal out of range 1
Action code Failure code Transmission oil temperature sensor input signal out of 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?) or only transmission oil temperature is low (transmission oil temperature sensor signal cir-
trouble cuit voltage is above 4.56 V (below 15 ?) and torque converter and brake oil temperature sensor
voltage is below 3.7 V (above 55 ?).
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 (?), 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".

2) Disconnect connector T/M.T (CN23).
Defective transmission oil
1 Between Resis-
temperature sensor T/M.T Oil temperature: 25? 37 – 50 kz
tance
(CN23)
(male) (1) Oil temperature: 100? Resis-
3.5 – 4.0 kz
– (2) tance
2) Disconnect connectors ATC1 and T/M.T (CN23).
ness
– T/M.T (CN23) (female) (2) tance
contact)
Max. 1 z
– T/M.T (CN23) (female) (1) tance
and standard 2) Disconnect connectors ATC1 and T/M.T (CN23).
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) – T/M.T (CN23) (female) (1) tance
Hot short in wiring harness 3) Connect T-adapter.
4
(Contact with 24V) 4) Turn the starting switch ON.
Between ground and wiring harness ATC1
Voltage Max. 5 V
(female) (3) – T/M. T (CN23) (female) (1)
5
troller Between Oil temperature: 25? Resis-
37 – 50 kz
ATC1 tance
(female) Resis-
Oil temperature: 100? 3.5 – 4.0 kz
(3) – (21) tance
90 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 91
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor rear

wheel system (Ground fault) 1
Action code Failure code Trouble in retarder oil temperature sensor rear wheel system
Trouble (Ground fault)
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 (?) and 30212 (V)).

a Prepare with starting switch OFF, disconnect connector RTR
and troubleshooting with starting switch still OFF.
Retarder oil tempera-
RTR (male) Resistance (kz)
ture (?)
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 (?)
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 (?)
(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: 30211).
92 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 93
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 ?) 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 ?)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55 ? )
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 (?) and 32702) (V))
information 2) Torque converter oil temperature sensor (codes: 30100 (?) and 30101 (V))
3) Retarder oil temperature sensor (codes: 30211 (?) 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 ? tance
(male) (1) Oil temperature: Resis-
3.5 – 4.0 kz
– (2) 100 ? 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- Min. 1
between ATC1 (female) (20) – STR (female)
tance Mz
(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 ? tance
(female) Oil temperature: Resis-
(20) – (21) 100 ? 3.5 – 4.0 kz
tance
94 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 95
Failure code [DGT1KX] Torque converter oil temperature sensor input

signal out of range 1
Action code Failure code Torque converter oil temperature sensor input signal out of 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?) 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?).
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

2) Disconnect connector T/C. T (CN22).
Defective torque converter Between Resis-
1 Oil temperature: 25? 37 – 50 kz
oil temperature sensor T/C.T tance
(CN22)
(male) (1) Oil temperature: 100? Resis-
3.5 – 4.0 kz
– (2) tance
2) Disconnect connectors ATC1 and T/C.T (CN22).
ness
– T/C.T (CN22) (female) (2) tance
contact)
Max. 1 z
– T/C.T (CN22) (female) (1) tance
and standard 2) Disconnect connectors ATC1 and T/C.T (CN22).
value in normal Grounding fault in wiring har- 3) Connect T-adapter.
3
state ness
Between ground and wiring harness ATC1 Resis-
Min. 1 Mz
(female) (9) – T/C.T (CN22) (female) (1) tance
2) Disconnect connectors ATC1 and T/C.T (CN22).
Befective hot short in wiring 3) Insert T-adapter.
4
harness 4) Turn the starting switch ON.
Between ground and wiring harness ATC1
Voltage Max. 1 V
(female) (21) – T/C.T (CN22) (female) (2)
5
troller Between Oil temperature: 25? Resis-
37 – 50 kz
AT1 tance
(female) Resis-
Oil temperature: 100? 3.5 – 4.0 kz
(9) – (21) tance
96 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 97
HD465-7E0, HD605-7E0 98
HD465-7E0, HD605-7E0 99
HD465-7E0, HD605-7E0 100


© 2009 KOMATSU
All Rights Reserved
101 HD465-7E0, HD605-7E0

SEN01667-04
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
(Exhaust gas temperature sensor (F): Disconnection) ............................................................................ 4
(Exhaust gas temperature sensor (F): Short circuit)................................................................................ 6
(Exhaust gas temperature sensor (R): Disconnection)............................................................................ 8
(Exhaust gas temperature sensor (R): Short circuit) ............................................................................. 10
(Blow-by pressure sensor: Short circuit)................................................................................................ 12
(Blow-by pressure sensor: Short circuit with power supply line)............................................................ 14
Short circuit in suspension pressure sensor system (Front right).......................................................... 16
Disconnection or ground fault in suspension pressure sensor system (Front right) .............................. 18
HD465-7E0, HD605-7E0 1

Short circuit in suspension pressure sensor system (Front left) ............................................................ 20
Disconnection or ground fault in suspension pressure sensor system (Front left) ................................ 22
Failure code [DHP6KA] Trouble in suspension pressure sensor system (Right rear)................................... 24
Failure code [DHP6KX] Trouble in suspension pressure sensor system (Right rear)................................... 26
Short circuit in suspension pressure sensor system (Right rear)........................................................... 28
Disconnection or ground fault in suspension pressure sensor system (Right rear)............................... 30
Failure code [DHP7KA] Trouble in suspension pressure sensor system (Left rear) ..................................... 32
Failure code [DHP7KX] Trouble in suspension pressure sensor system (Left rear) ..................................... 34
Short circuit in suspension pressure sensor system (Left rear) ............................................................. 36
Disconnection or ground fault in suspension pressure sensor system (Left rear) ................................. 38
Failure code [DHT5KX] Disconnection, ground fault in torque converter inlet oil pressure sensor............... 40
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor....................................................... 42
Failure code [DHU2KX] Trouble in front accumulator oil pressure sensor.................................................... 44
Failure code [DHU3KX] Trouble in rear accumulator oil pressure sensor..................................................... 46
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................................... 48
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) ...................................... 50
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)..................................... 52
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)....................................... 54
Failure code [DJF1KA] Disconnection in fuel level sensor............................................................................ 56
Failure code [DK30KX] Trouble in steering angle potentiometer .................................................................. 57
Failure code [DK51L5] Trouble in manual retarder potentiometer and retarder swich signal ....................... 58
Failure code [DK52KX] Trouble 1 in hoist lever potentiometer sensor.......................................................... 62
Failure code [DK53L8] Trouble 2 in hoist lever potentiometer sensor .......................................................... 64
Failure code [DK54KX] Trouble in body positioner sensor............................................................................ 66
Failure code [DKD0L6] Trouble in steering speed sensor............................................................................. 68
Failure code [DKH0KX] Clinometer sensor signal out of range .................................................................... 70
Failure code [DKH1KX] (or VHMS_LED display: “n4” o “33”) Abnormality in clinometer sensor................. 72
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system............................. 74
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................................... 76
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system................. 78
Failure code [DLF2LC] Trouble in transmission intermediate shaft speed sensor........................................ 80
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3

(Exhaust gas temperature sensor (F): Disconnection) 1
Action code Failure code Exhaust gas temperature sensor (F): Disconnection
Trouble
— DGT4KA (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 0.5 V
trouble or less.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
• The LED of the VHMS controller displays “n3” o “12”.
Related • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
information monitoring function (Code: 42610 EXHAUST TEMP F).
• If failure code [DBB6KP] (VHMS controller 24V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
Defective exhaust gas tem- HM-21A Voltage
temperature
perature sensor on the
1 50 – 100°C 1.0 – 35 mV
engine front side (Internal
short circuit) 300 – 400°C 11.2 – 15.6 mV
Between (1) and (2)
500 – 600°C 19.7 – 24.2 mV
700 – 800°C 28.1 – 32.6 mV
troubleshooting.
Exhaust gas
HM-23A Voltage
Defective exhaust gas tem- temperature
perature sensor amplifier on Between (A) and (C) Normal 20 – 30 V
2
the engine front side
Possible 50 – 100°C 1.0 – 1.6 V
(Internal short circuit)
causes and 300 – 400°C 2.1 – 2.7 V
standard value Between (B) and (C)
500 – 600°C 2.9 – 3.6 V
in normal state
700 – 800°C 3.8 – 4.4 V
ness Wiring harness between HM-23A (female) Resis-
3 Max. 1 z
(Disconnection or defective (B) – HM-CN2A (female) (7) tance
contact of connector) Wiring harness between HM-21A (female) Resis-
Max. 1 z
(2) – HM-22A (female) (2) tance
troubleshooting.
Exhaust gas
HM-CN2A Voltage
temperature
4 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
4 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5

(Exhaust gas temperature sensor (F): Short circuit) 1
Action code Failure code Exhaust gas temperature sensor (F): Short circuit
Trouble
— DGT4KB (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 4.9 V
trouble and above.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
information • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
monitoring function (Code: 42610 EXHAUST TEMP F).

troubleshooting.
Exhaust gas
HM-21A Voltage
temperature
50 – 100°C 1.0 – 3.5 mV
Defective exhaust gas tem-
perature sensor on the 300 – 400°C 11.2 – 15.6 mV
1 Between (1) and (2)
engine front side (Internal 500 – 600°C 19.7 – 24.2 mV
HM-21A (male) Resistance
Between (1) and (2) Min. 1 Mz
troubleshooting.
Exhaust gas
Possible HM-23A Voltage
temperature
causes and
standard value Between (A) and (C) Normal 20 – 30 V
in normal state 50 – 100°C 1.0 – 1.6 V
perature sensor amplifier on 300 – 400°C 2.1 – 2.7 V
2 Between (B) and (C)
the engine front side 500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
HM-23A (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Wiring harness between HM-23A (female)
Hot short in wiring harness (B) – HM-CN2A (female) (7) and chassis Voltage Max. 1 V
3
(Contact with 24 V circuit) ground
(2) –HM-22A (female) (2) and chassis Voltage Max. 1 V
ground
6 HD465-7E0, HD605-7E0

Grounding fault in wiring har- Resis-
(B) – HM-CN2A (female) (7) and chassis Min. 1 Mz
4 ness tance
ground
Possible Resis-
(2) – HM-22A (female) (2) and chassis Min. 1 Mz
causes and tance
ground
standard value a Prepare with starting switch OFF, then start engine and carry out
in normal state troubleshooting.
Exhaust gas
HM-CN2A Voltage
temperature
5 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
HD465-7E0, HD605-7E0 7

(Exhaust gas temperature sensor (R): Disconnection) 1
Action code Failure code Exhaust gas temperature sensor (R): Disconnection
Trouble
— DGT5KA (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 0.5 V or
trouble less.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
information monitoring function (Code: 42611 EXHAUST TEMP R).

troubleshooting.
Exhaust gas
Defective exhaust gas tem- HM-21B Voltage
temperature
perature sensor on the
1 50 – 100°C 1.0 – 3.5 mV
engine rear side (Internal
Between (1) and (2)
500 – 600°C 19.7 – 24.2 mV
700 – 800°C 28.1 – 32.6 mV
troubleshooting.
Exhaust gas
HM-23B Voltage
Defective exhaust gas tem- temperature
perature sensor amplifier on Between (A) and (C) Normal 20 – 30 V
2
the engine rear side
Possible 50 – 100°C 1.0 – 1.6 V
causes and 300 – 400°C 2.1 – 2.7 V
standard value Between (B) and (C)
500 – 600°C 2.9 – 3.6 V
in normal state
700 – 800°C 3.8 – 4.4 V
ness Wiring harness between HM-23B (female) Resis-
3 Max. 1 z
(Disconnection or defective (B) – HM-CN2A (female) (5) tance
contact of connector) Wiring harness between HM-21B (female) Resis-
Max. 1 z
(2) – HM-22B (female) (2) tance
troubleshooting.
Exhaust gas
HM-CN2A Voltage
temperature
4 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
8 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 9

(Exhaust gas temperature sensor (R): Short circuit) 1
Action code Failure code Exhaust gas temperature sensor (R): Short circuit
Trouble
— DGT5KB (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 4.9 V
trouble and above.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
information • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
monitoring function (Code: 42611 EXHAUST TEMP R).

troubleshooting.
Exhaust gas
HM-21B Voltage
temperature
50 – 100°C 1.0 – 3.5 mV
perature sensor on the 300 – 400°C 11.2 – 15.6 mV
1 Between (1) and (2)
engine rear side (Internal 500 – 600°C 19.7 – 24.2 mV
HM-21B (male) Resistance
Between (1) and (2) Min. 1 Mz
troubleshooting.
Possible Exhaust gas
HM-23B Voltage
causes and temperature
standard value Between (A) and (C) Normal 20 – 30 V
in normal state 50 – 100°C 1.0 – 1.6 V
perature sensor amplifier on 300 – 400°C 2.1 – 2.7 V
2 Between (B) and (C)
the engine rear side 500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
HM-23B (male) Resistance
Min. 1 Mz
chassis ground
Wiring harness between HM-23B (female)
Hot short in wiring harness (B) – HM-CN2A (female) (5) and chassis Voltage Max. 1 V
3
(2) – HM-22B (female) (2) and chassis Voltage Max. 1 V
ground
10 HD465-7E0, HD605-7E0

(B) – HM-CN2A (female) (5) and chassis Min. 1 Mz
4 ness tance
ground
Possible Resis-
(2) – HM-22B (female) (2) and chassis Min. 1 Mz
causes and tance
ground
standard value a Prepare with starting switch OFF, then start engine and carry out
in normal state troubleshooting.
Exhaust gas
HM-CN2A Voltage
temperature
5 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
HD465-7E0, HD605-7E0 11

(Blow-by pressure sensor: Short circuit) 1
Action code Failure code Blow-by pressure sensor: Short circuit
Trouble
— DHE5KB (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 0.1 V or less.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• Method of reproducing failure code: Start engine and performs troubleshooting

troubleshooting.
HM12 Engine speed Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Defective blow-by pressure Normal 0.50 – 4.50 V
sensor Between (C) and (A)
1 High idle 0.50 – 0.90 V
(Internal disconnection or
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
HM12 Resistance
Min. 1 Mz
chassis ground
Disconnection in wiring har- Wiring harness between HM-CN1 (female) Resis-
Max. 1 z
Possible ness (4), (5) – HM12 (female) (B) tance
causes and 2
(Disconnection or defective Wiring harness between HM12 (female) (C) Resis-
standard value contact of connector) Max. 1 z
– HM-CN2A (female) (18) tance
in normal state
Wiring harness between HM12 (female) (A) Resis-
Max. 1 z
– chassis ground tance
Wiring harness between HM-CN1 (female)
(4), (5) – HM12 (female) (B) and chassis Min. 1 Mz
3 ness tance
ground
Wiring harness between HM12 (female) (C)
Resis-
–HM-CN2A (female) (18) and chassis Min. 1 Mz
tance
ground
troubleshooting.
Defective VHMS & PLM HM-CN2A Engine speed Voltage
4
controller Normal 4.85 – 5.15 V
Between (18) and (12) Normal 0.50 – 4.50 V
High idle 0.50 – 0.90 V
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 13

(Blow-by pressure sensor: Short circuit with power supply line) 1
Action code Failure code Blow-by pressure sensor: Short circuit with power supply line
Trouble
— DHE5KY (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 4.7 V and above.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
information • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
• Method of reproducing failure code: Start engine and performs troubleshooting

troubleshooting.
HM12 Engine speed Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Defective blow-by pressure Normal 0.50 – 4.50 V
Between (C) and (A)
1 sensor High idle 0.50 – 0.90 V
HM12 Resistance
Min. 1 Mz
Possible chassis ground
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting
in normal state
Wiring harness between HM-CN1 (female)
Hot short in wiring harness (4), (5) – HM12 (female) (B) and chassis Voltage Max. 1 V
2
Wiring harness between HM12 (female) (C)
– HM-CN2A (female) (18) and chassis Voltage Max. 1 V
ground
troubleshooting.
Defective VHMS & PLM HM-CN2A Engine speed Voltage

3
controller Normal 4.85 – 5.15 V
Between (18) and (12) Normal 0.50 – 4.50 V
High idle 0.50 – 4.50 V
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15

Short circuit in suspension pressure sensor system (Front right) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front right)
Trouble
E01 DHP4KY (VHMS controller system) (Display: PLM)
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front right).
trouble
Action of
controller
Problem that
appears on • PLM may not be displayed normally.
machine
Related
information • Suspension pressure can be checked with the monitoring function (Code: 32804 (MPa) and 32810
(V)).

2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
3) Connect T-branch.
Disconnection in wiring Wiring harness between HM-CN2B (female) Resis-
harness Max. 1 z
1 (1) – SUFR (female) (C) tance
contact of connector) Wiring harness between HM-CN2B (female) Resis-
Max. 1 z
(9) – SUFR (female) (A) tance
Wiring harness between HM-CN1 (female) Resis-
Max. 1 z
(2) – SUFR (female) (B) tance
2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Ground fault in wiring 3) Connect T-branch to HM-CN1 and HM-CN2B (female).
2 harness Between wiring harness HM-CN2B (female) Resis-
Min. 1 Mz
(Contact with ground circuit) (1) – SUFR (female) (C) and ground tance
Possible causes Between wiring harness HM-CN1 (female) Resis-
Min. 1 Mz
and standard (2) – SUFR (female) (B) and ground tance
value in normal 1) Turn the starting switch OFF.
state 2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Hot short in wiring harness 3) Connect T-branch to HM-CN2B (female).
Between wiring harness HM-CN2B (female)
Voltage Max. 1 V
(1) – SUFR (female) (C) and ground
2) Disconnect connector SUFR.
Defective suspension 3) Connect T-branch.
pressure sensor (FR)
Between SUFR (B) – (A) Voltage 18 ± 3 V
Between SUFR (C) – (A) Voltage 1.0 – 4.6 V
2) Disconnect connector HM-CN2B.
Defective VHMS & PLM 3) Connect T-branch to HM-CN2B.
5
controllers 4) Turn the starting switch ON.
Between HM-CN2B (1) – (9) Voltage 1.0 – 4.6 V
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17

Disconnection or ground fault in suspension pressure sensor system
(Front right) 1
Action code Failure code Disconnection or ground fault in suspension pressure sensor sys-
Trouble tem (Front right)
E01 DHP4KZ (VHMS controller system) (Display: PLM)
Contents of • No signal received from the suspension pressure sensor (front right) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

and standard
value in normal Carry out troubleshooting for failure code [DHP4KY].
state
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19

Short circuit in suspension pressure sensor system (Front left) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front left)
Trouble
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front left).
trouble
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
harness Max. 1 z
1 (2) – SUFL (female) (C) tance
Max. 1 z
(9) – SUFL (female) (A) tance
Max. 1 z
(2) – SUFL (female) (B) tance
2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Ground fault in wiring 3) Connect T-branch to HM-CN1 and HM-CN2B (female).
2 harness Between wiring harness HM-CN2B (female) Resis-
Min. 1 Mz
(Contact with ground circuit) (2) – SUFL (female) (C) and ground tance
Possible causes Between wiring harness HM-CN1 (female) Resis-
Min. 1 Mz
and standard (2) – SUFL (female) (B) and ground tance
state 2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Hot short in wiring harness 3) Connect T-branch to HM-CN2B (female).
Between wiring harness HM-CN2B (female)
Voltage Max. 1 V
(2) – SUFL (female) (C) and ground
2) Disconnect connector SUFL.
Defective suspension 3) Connect T-branch.
pressure sensor (FL)
Between SUFL (B) – (A) Voltage 18 ± 3 V
Between SUFL (C) – (A) Voltage 1.0 – 4.6 V
2) Disconnect connector HM-CN2B.
Defective VHMS & PLM 3) Connect T-branch to HM-CN2B.
5
controllers 4) Turn the starting switch ON.
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21

(Front left) 1
Trouble tem (Front left)
Contents of • No signal received from the suspension pressure sensor (front left) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

and standard
state
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Failure code [DHP6KA] Trouble in suspension pressure sensor system

(Right rear) 1
Action code Failure code Trouble in suspension pressure sensor system (Right rear)
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 (Right rear) signal can be checked with the monitoring function (Code:
Related
32816 (MPa), 32817 (V)).
information
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
Disconnection in wiring Wiring harness between BRC1 (female) (7) Resis-
harness Max. 1 z
1 – SURR (female) (C) tance
contact of connector) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(21) – SURR (female) (A) tance
Max. 1 z
(2) – SURR (female) (B) tance
Grounding fault in wiring
Between wiring harness BRC1 (female) (7) Resis-
2 harness Min. 1 Mz
– SURR (female) (C) and ground tance
Resis-
Possible causes between BRC1 (female) (21) – SURR Min. 1 Mz
tance
and standard (female) (A)
state 2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
Defective hot short in wiring 3) Connect T-adapter to BRC1 (female).
3 harness 4) Turn starting switch ON.
(Contact with 24 V 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
Between BRC1 (7) – (21) Voltage 1.0 – 4.6 V
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
Failure code [DHP6KX] Trouble in suspension pressure sensor system

(Right rear) 1
Action code Failure code Trouble in suspension pressure sensor system (Right rear)
Trouble
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
• This trouble can be checked with monitoring function (Code: 32816 (MPa), 32817 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [DH6KA].
state
26 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 27

Short circuit in suspension pressure sensor system (Right rear) 1
Action code Failure code Short circuit in suspension pressure sensor system (Right rear)
Trouble
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
information • Suspension pressure can be checked with monitoring function (Code: 32806 (MPa), 32812 (V)).

harness Max. 1 z
1 (7) – SURR (female) (C) tance
Max. 1 z
(9) – SURR (female) (A) tance
Max. 1 z
(2) – SURR (female) (B) tance
3) Connect T-adapter to HM-CN1 (female) and HM-2B (female).
Between wiring harness HM-CN2B (female) Resis-
2 harness Min. 1 Mz
(7) – SURR (female) (C) and ground tance
Resis-
Possible causes between HM-CN1 (female) (2) – SURR Min. 1 Mz
tance
and standard (female) (B)
state 2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
Defective hot short in wiring 3) Connect T-adapter to HM-CN2B (female).
between HM-CN2B (female) (7) – SURR Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURR.
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 VHMS & PLM 3) Insert T-adapter.
5
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29

(Right rear) 1
Trouble tem (Right rear)
Contents of
• Signal is not sent from suspension pressure sensor (right rear) or it is grounded (Abnormal).
trouble
Action of
controller
Problem that
machine

and standard
state
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
Failure code [DHP7KA] Trouble in suspension pressure sensor system

(Left rear) 1
Action code Failure code Trouble in suspension pressure sensor system (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 or
trouble above 4.6V.
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure (Left rear) signal can be checked with the monitoring function (Code:
Related
32814 (MPa), 32815 (V)).
information
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors BRC1, SURL, HM-CN1 and HM-CN2B.
harness Max. 1 z
1 – SURL (female) (C) tance
contact of connector) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(21) – SURL (female) (A) tance
Max. 1 z
(2) – SURL (female) (B) tance
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 BRC1 (female) (21) – SURL Min. 1 Mz
and standard tance
(female) (A)
value in normal
2) Disconnect connectors BRC1, SURL and HM-CN2B.
3
between BRC1 (female) (1) – SURL Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURL.
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.
32 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 33
Failure code [DHP7KX] Trouble in suspension pressure sensor system

(Left rear) 1
Action code Failure code Trouble in suspension pressure sensor system (Left rear)
Trouble (When ARSC is not set or ARSC system switch is "ON")
E03 DHP7KX (Retarder controller system)
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
Related
• This trouble can be checked with monitoring function (Code: 32814 (MPa), 32815 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [DHP7KA].
state
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35

Short circuit in suspension pressure sensor system (Left rear) 1
Action code Failure code Short circuit in suspension pressure sensor system (Left rear)
Trouble
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor.
trouble
Action of
controller
Problem that
machine

harness Max. 1 z
1 (8) – SURL (female) (C) tance
Max. 1 z
(9) – SURL (female) (A) tance
Max. 1 z
(2) – SURL (female) (B) tance
3) Connect T-adapter to HM-CN1 (female) and HM-CN2B (female).
Resis-
2 harness between HM-CN2B (female) (8) – SURL Min. 1 Mz
tance
(Contact with ground circuit) (female) (C)
between HM-CN1 (female) (2) – SURL Min. 1 Mz
and standard tance
(female) (B)
value in normal
2) Disconnect connectors BRC1, SURL and HM-CN2B.
3) Connect T-adapter to HM-CN2B (female).
3
between HM-CN2B (female) (8) – SURL Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURL.
pressure sensor (Left rear)
Between SURL (B) – (A) Voltage 18 ± 3 V
Between SURL (C) – (A) Voltage 1.0 – 4.6 V
Defective VHMS & PLM 3) Insert T-adapter.
5
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37

(Left rear) 1
Trouble tem (Left rear)
Contents of
• Signal is not sent from suspension pressure sensor or it is grounded (Abnormal).
trouble
Action of
controller
Problem that
machine

and standard
state
38 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 39
Failure code [DHT5KX] Disconnection, ground fault in torque converter

inlet oil pressure sensor 1
Action code Failure code Disconnection, ground fault in torque converter inlet oil pressure
Trouble sensor
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 T/C.P (CN21).
Disconnection in wiring Wiring harness between ATC3(female) (8) – Resis-
harness Max. 1 z
1 T/C.P (CN21) (female) (B) tance
contact) Wiring harness between ATC1(female) (21) Resis-
Max. 1 z
– T/C.P (CN21) (female) (A) tance
Max. 1 z
– T/C.P (CN21) (female) (C) tance
2) Disconnect connectors ATC3 and T/C.P (CN21).
Grounding fault in wiring Resis-
2 between ATC3A (female) (8) – T/C.P Min. 1 Mz
harness tance
(CN21) (female) (B)
Resis-
between ATC1 (female) (1) – T/C P (CN21) Min. 1 Mz
Possible causes tance
(female) (C)
and standard
state 2) Disconnect connectors ATC3 and T/C.P (CN21).
Defective hot short in wiring 4) Turn the starting switch ON.
3
harness Between ground and wiring har-
ness between ATC3 (female) (8)
– T/C.P (CN21) (female) (B) –
ground
2) Disconnect connector T/C.P (CN21).
Defective torque converter 3) Insert T-adapter.
inlet oil pressure sensor
Between T/C.P (CN21) (B) – (A) Voltage 20 – 30 V
Between T/C.P (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
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 1

Action code Failure code Trouble in torque converter oil pressure sensor
Trouble
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

2) Disconnect connectors ATC3 and T/C.P (CN21).
Defective hot short in wiring 3) Insert T-adapter.
harness
Wiring harness between ATC1 (female) (1)
Voltage Max. 1.2 V
– T/C.P (CN21) (female) (C)
Possible causes 2) Disconnect connector T/C.P (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 T/C.P (CN21) (B) – (A) Voltage 20 – 30 V
Between T/C.P (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
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
Failure code [DHU2KX] Trouble in front accumulator oil pressure

sensor 1
Action code Failure code Trouble in front accumulator oil pressure sensor
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
(a contact with 24 V circuit)
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
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 45
Failure code [DHU3KX] Trouble in rear accumulator oil pressure sensor1

Action code Failure code Trouble in rear accumulator oil pressure sensor
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
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
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 47
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front right)
Trouble
E03 DHU6KX (ABS controller system)
Contents of • Input voltage from ABS control valve pressure sensor (front right: FR) became 0.3 V or less or 4.7 V
trouble and over.
Action of
• Stop ABS control.
controller
Problem that
• ABS does not work.
appears on
machine • Ordinary brake operation can be carried out.
Related • ABS control valve pressure sensor output can be checked with the monitoring function (Code:
information 43314 (MPa) and 43315 (V)).

2) Disconnect connector ABS1 and BPFR.
3) Connect T-branch to ABS1 and BRFR.
Disconnection in wiring Wiring harness between ABS1 (female) (19) Resis-
harness Max. 1 z
1 – BPFR (female) (C) tance
contact in connector) Wiring harness between ABS1 (female) (21) Resis-
Max. 1 z
– BPFR (female) (A) tance
Wiring harness between ABS1 (female) (22) Resis-
Max. 1 z
– BPFR (female) (B) tance
3) Connect T-branch to ABS1 (female).
Ground fault in wiring
2 Between wiring harness ABS1 (female) (19) Resis-
harness Max. 1 Mz
– BPFR (female) (C) and ground tance
Possible causes
and standard Between wiring harness ABS1 (female) (22) Resis-
Max. 1 Mz
value in normal – BPFR (female) (B) and ground tance
state 1) Turn the starting switch OFF.
3) Connect T-branch to ABS1.
3 Hot short in wiring harness 4) Turn the starting switch ON.
Between wiring harness ABS1 (19) – BPFR
Voltage Max. 1 V
(female) (C) and ground
2) Disconnect connector BPFR.
Defective ABS control valve 3) Replace with the front left pressure sensor. (See [DHU7KX].)
4
pressure sensor (FR) 4) Turn the starting switch ON.
Failure code [DHU6KX] does not appear.
2) Disconnect connector ABS1.
5 Defective ABS controller 3) Connect T-branch.
Between ABS1 (19) + and (21) Voltage 0.3 – 4.7 V
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 49

(Front left) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (front left: FL) became 0.3 V or less or 4.7 V
trouble and over.
Action of
controller
Problem that
appears on

2) Disconnect connector ABS1 and BPFL.
harness Max. 1 z
1 – BPFL (female) (C) tance
Max. 1 z
– BPFL (female) (A) tance
Max. 1 z
– BPFL (female) (B) tance
harness Max. 1 Mz
– BPFL (female) (C) and ground tance
Possible causes
Max. 1 Mz
value in normal – BPFL (female) (B) and ground tance
Between wiring harness ABS1 (13) – BPFL
Voltage Max. 1 V
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the front right pressure sensor. (See [DHU6KX].)
4
pressure sensor (FR) 4) Turn the starting switch ON.
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 51

(Rear right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear right)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear right: RR) became 0.5 V or less or 4.7 V
trouble and over.
Action of
controller
Problem that
appears on

2) Disconnect connector ABS1 and BPRR.
harness Max. 1 z
1 – BPRR (female) (C) tance
Max. 1 z
– BPRR (female) (A) tance
Max. 1 z
– BPRR (female) (B) tance
harness Max. 1 Mz
– BPRR (female) (C) and ground tance
Possible causes
Max. 1 Mz
value in normal – BPRR (female) (B) and ground tance
Between wiring harness ABS1 (7) – BPRR
Voltage Max. 1 V
2) Disconnect connector BPRR.
Defective ABS control valve 3) Replace with the rear left pressure sensor. (See [DHU9KX].)
4
pressure sensor (RR) 4) Turn the starting switch ON.
52 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 53

(Rear left) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear left: RL) became 0.5 V or less or 4.7 V
trouble and over.
Action of
controller
Problem that
appears on

harness Max. 1 z
1 – BPRL (female) (C) tance
Max. 1 z
– BPRL (female) (A) tance
Max. 1 z
– BPRL (female) (B) tance
2) Disconnect connector ABS1 and BPRL.
harness Max. 1 Mz
– BPFL (female) (C) and ground tance
Possible causes
Max. 1 Mz
value in normal – BPRL (female) (B) and ground tance
Between wiring harness ABS1 (1) – BPRL
Voltage Max. 1 V
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the rear right pressure sensor. (See [DHU8KX].)
4
pressure sensor (RL) 4) Turn the starting switch ON.
54 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 55
Failure code [DJF1KA] Disconnection in fuel level sensor 1

Action code Failure code Disconnection in fuel level sensor
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
2) Disconnect connectors ATC1and FUEL.
Defective hot short in wiring 3) Connect T-adapter.
harness
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
56 HD465-7E0, HD605-7E0
Failure code [DK30KX] Trouble in steering angle potentiometer 1

Action code Failure code Trouble in steering angle potentiometer
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
1 Defective sensor Between (A) – (C) 5 kz ± 20%
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-
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) and ground Min. 1 Mz
tance
out.)
HD465-7E0, HD605-7E0 57
Failure code [DK51L5] Trouble in manual retarder potentiometer and

retarder swich signal 1
Action code Failure code Trouble in manual retarder potentiometer and retarder swich signal
Trouble
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
contact) Wiring harness between BRC1 (female) Resis-
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)
58 HD465-7E0, HD605-7E0

2) Disconnect connectors BRC1 and RTL.
Hot short in wiring Between ground and wiring harness
harness between BRC1 (female) (22) – RE1 (female) Voltage Max. 1 V
3 (1)
(Contact with power source
circuit) Between ground and wiring harness
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,
(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
HD465-7E0, HD605-7E0 59
60 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 61
Failure code [DK52KX] Trouble 1 in hoist lever potentiometer sensor 1

Action code Failure code Trouble 1 in hoist lever potentiometer sensor
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
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)
Hot short in wiring harness between BRC3 (female) (34) – HSL (female) Voltage Max. 1 V
3 (Contact with power source (4)
between BRC1 (female) (20) – HSL (female) Voltage Max. 1 V
(2)
between BRC1 (female) (19) – HSL (female) Voltage Max. 1 V
(3)
62 HD465-7E0, HD605-7E0

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)
HD465-7E0, HD605-7E0 63
Failure code [DK53L8] Trouble 2 in hoist lever potentiometer sensor 1

Action code Failure code Trouble 2 in hoist lever potentiometer sensor
(Out of total range of input signal voltage of lever potentiometer 1
Trouble
E03 DK53L8 or 2)
(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.
64 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 65
Failure code [DK54KX] Trouble in body positioner sensor 1

Action code Failure code Trouble in body positioner sensor
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.
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.
Resis-
2 harness between BRC1 (female) (8) – B07 (female) Min. 1 Mz
tance
(Contact with ground circuit) (B)
Possible causes
Resis-
value in normal between BRC3 (female) (34) – B07 (female) Min. 1 Mz
tance
state (C)
2) Disconnect connectors BRC1, BRC3B, and B07.
Hot short in wiring 4) Turn the starting switch ON.
harness Between ground and wiring harness
3
(Contact with power source between BRC1 (female) (8) – B07 (female) Voltage Max. 1 V
circuit) (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
66 HD465-7E0, HD605-7E0

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)
HD465-7E0, HD605-7E0 67
Failure code [DKD0L6] Trouble in steering speed sensor 1

Action code Failure code Trouble 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 Between ground and wiring harness between Resis-
harness Min. 1 Mz
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.
68 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 69
Failure code [DKH0KX] Clinometer sensor signal out of range 1

Action code Failure code Clinometer sensor signal out of range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of clinometer sensor has become below 0.5 V or above 4.5 V.
Action of
Problem that
appears on • Machine roll angle abnormality [989D00] cannot be detected.
machine
• Signal from clinometer 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 clinometer 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
contact) Wiring harness between ATC1 (female) (16) Resis-
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).
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
70 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 71
Failure code [DKH1KX] (or VHMS_LED display: “n4” o “33”)

Abnormality in clinometer sensor 1
Action code Failure code Abnormality in clinometer sensor
Trouble
E01 DKH1KX (VHMS controller system) (Display: PLM)
Contents of
• Abnormality (Disconnection or short circuit) was detected in signal from clinometer sensor.
trouble
controller • Cannot detect tipping over.
Problem that
appears on • Load weight is not displayed or recorded correctly.
machine
Related
information • Input signal from pitch angle sensor can be checked with monitoring function (Code: 32901 (°),
32902 (V)).

2) Connect T-adapter to PM3 (male).
1 Defective clinometer sensor 3) Turn starting switch ON.
Between PM3 (C) – (A) Voltage 20 – 30 V
Between PM3 (B) – (A) Voltage 0.5 – 4.5 V
2) Connect T-adapter to HM-CN1 (female), HM-CN2B (female) and
PM3 (female).
harness Max. 1 z
2 (3) – PM3 (female) (B) tance
Max. 1 z
(2) – PM3 (female) (C) tance
Wiring harness between HM-CN2B (female) Resis-
Max. 1 z
(9) – PM3 (female) (A) tance
Possible causes 2) Disconnect connectors HM-CN1, HM-CN2B and PM3.
and standard 3) Connect T-adapter to HM-CN1 (female), HM-CN2B (female).
value in normal
state Defective harness grounding Resis-
3 between HM-CN2B (female) (3) – PM3 Min. 1 Mz
(female) (B)
Resis-
between HM-CN1 (female) (2) – PM3 Min. 1 Mz
tance
(female) (C)
2) Disconnect connectors HM-CN2B and PM3.
Defective hot short in wiring 3) Connect T-adapter to HM-CN2B (female).
between HM-CN2B (female) (3) – PM3 Voltage Max. 4.6 V
(female) (B)
2) Connect T-adapter in HM-CN1, HM-CN2B.
Defective VHMS & PLM 3) Turn starting switch ON.
5
controller
Between HM-CN1 (2) – HM-CN2B (9) Voltage 20 – 30 V
Between HM-CN2B (3) – HM-CN2B (9) Voltage 0.5 – 4.5 V
72 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 73
Failure code [DLF1KA] Disconnection in transmission input shaft speed

sensor system 1
Action code Failure code Disconnection in transmission input shaft speed sensor system
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".
2) Disconnect connector N1 (CN3).
Defective transmission input
2 Resis- 500 –
shaft speed sensor Between N1 (CN3) (male) (1) – (2)
tance 1,000 z
Between N1 (CN3) (male) (1), (2) – ground Min. 1 Mz
and standard tance
state 2) Disconnect connectors ATC2 and N1 (CN3).
harness
– N1 (CN3) (female) (1) tance
contact)
Max. 1 z
4
troller
Resis- 500 –
Between ATC2 (female) (40) – (29)
tance 1,000 z
74 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 75
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor 1

Action code Failure code Trouble in transmission input shaft speed sensor
Trouble
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 N1 (CN3) (male) (1) – (2)
tance 1,000 z
Resis-
tance
2) Disconnect connectors ATC2 and N1 (CN3).
Grounding fault in wiring 3) Connect T-adapter.
2
Possible causes harness Between ground and wiring harness
and standard Resis-
between ATC2 (female) (40) – N1 (CN3) Min. 1 Mz
value in normal tance
(female) (1)
state
3
harness
between ATC2 (female) (40) – N1 (CN3) Voltage Max. 1 V
(female) (1)
4
troller
Resis- 500 –
tance 1,000 z
76 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 77
Failure code [DLF2KA] Disconnection in transmission intermediate

shaft speed sensor system 1
Action code Failure code Disconnection in transmission intermediate shaft speed sensor
Trouble system
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 N2 (CN4) (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors ATC2, N2 (CN4).
harness
contact)
Max. 1 z
4
troller
Resis- 500 –
tance 1,000 z
78 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 79
Failure code [DLF2LC] Trouble in transmission intermediate shaft

speed sensor 1
Action code Failure code Trouble in transmission intermediate shaft speed sensor
Trouble
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 N2 (CN4) (male) (1) – (2)
tance 1,000 z
Resis-
tance
2) Disconnect connectors ATC2 – N2 (CN4).
2
and standard Resis-
between ATC2 (female) (20) – N2 (CN4) Min. 1 Mz
(female) (1)
state
3
harness
between ATC2 (female) (20) – N2 (CN4) Voltage Max. 1 V
(female) (1)
4
troller
Resis- 500 –
tance 1,000 z
80 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 81

© 2009 KOMATSU
All Rights Reserved
82 HD465-7E0, HD605-7E0
SEN01668-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) ................................................... 3
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)............................................................... 4
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)...................................................... 5
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ................................................................. 6
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) .................................................... 8
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear) ............................................................. 10
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) ................................................ 12
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear) ................................................. 13
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) .................................................... 14
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear)................................................................ 16
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)................................................... 18
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear) .................................................... 19
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system........................... 20
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor.................................................. 22
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor ....................................... 24
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor ...................................... 26
HD465-7E0, HD605-7E0 1
Failure code [DV00KB] Short circuit in buzzer output ................................................................................... 28

Failure code [DW2AKA] Disconnection in main pressure variable valve output ........................................... 30
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit ................................... 32
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit......................................... 34
Failure code [DW2AL1] Defective reset of main pressure variable valve ..................................................... 36
Failure code [DW2ALH] Malfunction of main pressure variable valve .......................................................... 38
(Disconnection or short circuit) .............................................................................................................. 40
Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit) ........... 44
Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit)........... 46
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating).......................................... 50
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit ................................................ 52
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit................................................... 54
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit.................................................... 56
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) ....................................... 57
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system .......................................................... 58
Failure code [DWNDMA] Defective ABS cut-off valve (Front) ...................................................................... 60
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system........................................................... 62
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ....................................................................... 64
2 HD465-7E0, HD605-7E0
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front

right) 1
Action code Failure code Disconnection in wheel speed sensor (Front right)
Trouble
E03 DLF6KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front right: FR).
Action of
controller • Stop ABS control.
Problem that
appears on
Related
information • Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
Defective wheel speed
1
sensor (FR) WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
2) Disconnect WSFR and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 Between WSFR (female) (1) – ABS2 Resis-
(female) (40) tance
contact in connector)
Between WSFR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFR and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFR (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Between ABS2 (40) – WSFR (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (40) – Resis-
1,150 – 1,450 z
(29) tance
HD465-7E0, HD605-7E0 3
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1

Action code Failure code Trouble in wheel speed sensor (Front right)
Trouble
E03 DLF6L3 (ABS controller system)
Contents of • Input signal (pulse signal) from the wheel speed sensor (front right: FR) to ABS controller is abnor-
trouble mal.
Action of
controller
Problem that
appears on
Related
• Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).
information

and standard
value in normal Carry out troubleshooting for failure code [DLF6KA].
state
4 HD465-7E0, HD605-7E0
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front

left) 1
Action code Failure code Disconnection in wheel speed sensor (Front left)
Trouble
E03 DLF7KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front left: FL).
Action of
controller • Stop ABS control.
Problem that
appears on
Related
information • Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
1 Defective sensor
WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
2) Disconnect WSFL and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 Between WSFR (female) (1) – ABS2 Resis-
(female) (30) tance
contact in connector)
Between WSFL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFL and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFL (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Between ABS2 (30) – WSFL (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (30) – Resis-
1,150 – 1,450 z
(29) tance
HD465-7E0, HD605-7E0 5
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1

Action code Failure code Trouble in wheel speed sensor (Front left)
Trouble
Contents of • Input signal (pulse signal) from the wheel speed sensor (front left: FL) to ABS controller is abnor-
trouble mal.
Action of
controller
Problem that
appears on
Related
• Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).
information

and standard
state
6 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 7
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right

rear) 1
Action code Failure code Disconnection in wheel speed sensor (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
1 Defective 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
connector) Between WSRR (female) (2) – BRC2 Resis-
state 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) and 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.)
8 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 9
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear) 1

Action code Failure code Trouble in wheel speed sensor (Right rear)
Trouble
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 Defective 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.
2 (Disconnection in wiring Between WSRR (female) (1) – ABS2 Resis-
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) and ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
10 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 11
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right

rear) 1
Action code Failure code Trouble in wheel speed sensor system (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
state
12 HD465-7E0, HD605-7E0
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right

rear) 1
Action code Failure code Disconnection in wheel speed sensor (Right rear)
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
HD465-7E0, HD605-7E0 13
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left

rear) 1
Action code Failure code Disconnection in wheel speed sensor (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
1 Defective 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
in connector) Between WSRL (female) (2) – BRC2 Resis-
state Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) and ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear) 1

Action code Failure code Trouble in wheel speed sensor (Left rear)
Trouble
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 Defective 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.
2 (Disconnection in wiring Between WSRL (female) (1) – ABS2 Resis-
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) and ground Resis-
Min. 1 Mz
tance
carried out.)
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)1
Action code Failure code Trouble in wheel speed sensor system (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
state
18 HD465-7E0, HD605-7E0
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear)1

Action code Failure code Disconnection in wheel speed sensor (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
HD465-7E0, HD605-7E0 19
Failure code [DLT3KA] Disconnection in transmission output shaft

speed sensor system 1
Action code Failure code Disconnection in transmission output shaft speed sensor system
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 A1 (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 N3 (CN5) (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors BRC2, ATC2, N3 (CN5).
Disconnection in wiring 3) Connect T-adapter to ATC2 (female) and N3 (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
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21
Failure code [DLT3LC] Trouble in transmission output shaft speed

sensor 1
Action code Failure code Trouble in transmission output shaft speed sensor
Trouble
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 N3 (CN5) (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, and N3 (CN5).
2
and standard Resis-
between ATC2 (female) (30) – BRC2 Min. 1 Mz
(female) (30), – N3 (CN5) (female) (1)
state
2) Disconnect connectors ATC2, BRC2, N3 (CN5).
3
harness
between ATC2 (female) (30) – BRC2 Voltage Max. 1 V
(female) (30), – N3 (CN5) (female) (1)
Defective transmission 3) Connect T-adapter.
4
controller
Resis- 500 –
tance 1,000 z
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Failure code [DLT4KA] Disconnection in transmission output shaft

speed sensor 1
Action code Failure code Disconnection in transmission output shaft speed sensor
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 A1 (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.
1 transmission output shaft
speed sensor
sion speed sensor".
2) Connect T-adapter to connector N3 (CN5) (male).
Defective transmission Resis- 500 –
2 Between N3 (CN5) (male) (1) – (2)
output shaft speed sensor tance 1,000 z
Resis-
Possible causes Between N3 (CN5) (male) (1), (2) – ground Min. 1 Mz
tance
and standard
state 2) Disconnect connectors ATC2, BRC2, and N3 (CN5).
Disconnection in wiring 3) Connect T-adapter to BRC2 (female) and N3 (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
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
Failure code [DLT4MA] Disconnection in transmission output shaft

speed sensor 1
Action code Failure code Disconnection in transmission output shaft speed sensor
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
Related • Transmission output shaft speed can be checked with monitoring function (Code: 31400 (V), 31403
information (rpm)). Wheel speed can be also checked with monitoring function (Code: 39704 (rpm)).

1 Resis- 500 –
tance 1,000 z
Resis-
tance
2) Disconnect connectors ATC2, BRC2, PM5, and N3 (CN5).
2 Between ground and wiring harness
harness
Possible causes between BRC2 (female) (30) – ATC2 Resis-
(female) (30), – PM5 (female) (7), – N3 tance
value in normal (CN5) (female) (1)
state
2) Disconnect connectors BRC2, ATC2, PM5, and N3 (CN5).
Disconnect hot short in 4) Turn the starting switch ON.
3
wiring harness Between ground and wiring harness
between ATC2 (female) (30) – BRC2
Voltage Max. 1 V
(female) (30), – PM5 (female) (7), – N3
(CN5) (female) (1)
2) Disconnect connector BRC2 and ATC2.
4 Defective reterder controller 3) Connect T-adapter.
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
26 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 27
Failure code [DV00KB] Short circuit in buzzer output 1

Action code Failure code Short circuit in buzzer output
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.
controller • 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)
Grounding fault in wiring a Turn starting switch OFF and disconnect BZ2, then carry out
harness troubleshooting without turning starting switch ON.
2
(Contact with ground circuit) Resis-
(Reference) Between DPC1 (male) (13) and ground 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) and 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) (Reference) 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.)
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29
Failure code [DW2AKA] Disconnection in main pressure variable valve

output 1
Action code Failure code Disconnection in main pressure variable valve output
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 Output current (0 – 1,000 (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
M/P. PS (CN27) (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 J05 (male) (12) –(13) 5 – 15 z
or defective contact in tance
connector) Resis-
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.)
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
Failure code [DW2AKB] Ground fault in main pressure variable valve

output circuit 1
Action code Failure code Ground fault in main pressure variable valve output circuit
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
M/P. PS (CN27) (male) Resistance
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect M/P. PS (CN27), then
Grounding fault in wiring carry out troubleshooting without turning starting switch ON.
2 harness
(Contact with ground circuit) Between ATC3 (female) (37) and ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect M/P. PS (CN27), then
Short circuit in wiring carry out troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Between ATC3 (female) (37) and ATC3 Resis-
Min. 1 Mz
(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
circuit) in wiring harness
Between ATC3 (female) (37) and ground Voltage Max. 1 V
If causes 1 – 4 are not detected, transmission controller may be
controller
carried out.)
32 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 33
Failure code [DW2AKY] Hot short in main pressure variable valve

output circuit 1
Action code Failure code Hot short in main pressure variable valve output circuit
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
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35
Failure code [DW2AL1] Defective reset of main pressure variable valve1

Action code Failure code Defective reset of main pressure variable valve
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
M/P. SW (CN26) (male) Resistance
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.
a Turn starting switch OFF and disconnect M/P. SW (CN26), then
Possible causes Grounding fault in wiring carry out troubleshooting without turning starting switch ON.
and standard 4 harness
(Contact with ground circuit) Between ATC2 (female) (7) and ground Resis-
value in normal Min. 1 Mz
tance
state
a Turn starting switch OFF and disconnect M/P. SW (CN26), then
5 harness
(with another wiring harness) Between ATC2 (female) (7) and ATC Resis-
Min. 1 Mz
(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) and ground Voltage Max. 1 V
If causes 1 – 6 are not detected, transmission controller may be
controller
carried out.)
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37
Failure code [DW2ALH] Malfunction of main pressure variable valve 1

Action code Failure code Malfunction of main pressure variable valve
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
38 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 39
Failure code [DW35KZ] Trouble in output system of auto suspension

solenoid 1 (Disconnection or short circuit) 1
Action code Failure code Trouble in output system of auto suspension solenoid 1 (Discon-
Trouble nection 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 (male) (1) – (2) 15 – 35 z
tance
Resis-
Between S04 (male) (1), (2) – ground Min. 1 Mz
tance
harness
Possible causes (Disconnection or defective Max. 1 z
– S04 (female) (1) tance
value in normal Wiring harness between BRC3 (female) (3) Resis-
Max. 1 z
state – S04 (female) (2) tance
2) Disconnect BRC3 and S04.
Hot short in wiring harness 3) Connect T-adapter to BRC3 (female).
3 (Contact with power supply 4) Turn starting switch ON.
between BRC3 (female) (7) – S04 (female) Voltage Max. 1 V
(1)
Resis-
Between BRC3 (female) (7) – (3) 15 – 35 z
tance
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41
Failure code [DW36KZ] Trouble in output system of auto suspension

solenoid 2 (Disconnection or short circuit) 1
Action code Failure code Trouble in output system of auto suspension solenoid 2 (Discon-
Trouble nection 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 (male) (1) – (2) 15 – 35 z
tance
Resis-
Between S05 (male) (1), (2) – ground Min. 1 Mz
tance
harness
– S05 (female) (1) tance
value in normal Wiring harness between BRC3 (female) (3) Resis-
Max. 1 z
state – S05 (female) (2) tance
2) Disconnect BRC3 and S05.
between BRC3 (female) (37) – S05 (female) Voltage Max. 1 V
(1)
Resis-
Between BRC3 (female) (37) – ground 15 – 20 z
tance
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
Failure code [DW72KZ] Trouble in kick-out solenoid output system

Action code Failure code Trouble in kick-out solenoid output system (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 circuit) Between ground and wiring harness
and standard
between BRC3 (female) (27) – LK0 (female) Voltage Max. 1 V
value in normal
(1)
state
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%
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 45
Failure code [DW73KZ] Trouble in hoist select valve output system

Action code Failure code Trouble 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.
2
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-
tance
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 47
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear

wheel) output system (Disconnection or short circuit) 1
Action code Failure code Trouble in brake cooling valve (BCV) (rear wheel) output system
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
(male: Relay side)
Between (1) – (2) 100 – 500 z
2 harness
(Contact with ground circuit) Between R14 (female) (1) and 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.)
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 49
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps

operating) 1
Action code Failure code Trouble in ASR shut-off valve (Valve keeps operating)
Trouble
E01 DWNBK4 (Retarder controller system)
Contents of
• Sensor does not respond to shut-off valve OFF command of retarder controller.
trouble
Action of
• Stops controlling ASR.
controller
Problem that
machine
• Sensor is turned OFF when pressure is 0.3 (MPa) {3 kg/cm²} or less. (In range of 0.3 (MPa) {3 kg/
Related
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.
a Make jig by connecting wires to T-adapter for DT-T-2.
2) Disconnect ASR7 and insert jig in ASR7 (male) (Keep ASR7
(female) disconnected).
3) Prepare and turn starting switch ON.
2 Defective sensor 4) Turn ASR switch ON and OFF and carry out troubleshooting.
Both ends of jig: Between ASR7
Resistance
(male) (1) – ASR7 (male) (2)
Possible causes
Turn ASR switch OFF Min. 1 Mz
and standard
value in normal Turn ASR switch ON Max. 1 z
state 3 Defective air piping Air piping may be defective. Check it directly.
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-
4 (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
5 harness
(Contact with ground circuit) Between ASR7 (female) (1) and ground Resis-
Min. 1 Mz
tance
out.)
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 51
Failure code [DWNBKA] Disconnection in ASR shut-off valve output

circuit 1
Action code Failure code Disconnection in ASR shut-off valve output circuit
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
Between J04 (male) (42) – (43) 5 – 15 z
connector) Resis-
tance
If causes 1 and 2 are not detected, retarder controller may be
carried out.)
52 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 53
Failure code [DWNBKB] Ground fault in ASR shut-off valve output

circuit 1
Action code Failure code Ground fault in ASR shut-off valve output circuit
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
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) and ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect BRC3 and ASR2, then
state
3 harness
(with another wiring harness) Between BRC3 (female) (15) – BRC3 Resis-
Min. 1 Mz
(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) and ground Voltage Max. 1 V
out.)
54 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 55
Failure code [DWNBKY] Short circuit in ASR shut-off valve output

circuit 1
Action code Failure code Short circuit in ASR shut-off valve output 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
56 HD465-7E0, HD605-7E0
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not
operate) 1
Action code Failure code Trouble in ASR shut-off valve (Valve does not operate)
Trouble
E01 DWNBKY (Retarder controller system)
Contents of
• 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.
• Sensor is turned ON when pressure is 0.7 (MPa) {7 kg/cm²} or above. (In range of 0.3 (MPa)
Related
{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
HD465-7E0, HD605-7E0 57
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system 1

Action code Failure code Trouble in ABS cut-off valve (Front) system
Trouble
E03 DWNDKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Front) (CUTF).
trouble
• The current flows when ABS cut-off valve relay (Front) (CUTF) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Front)(CUTF).
controller (Stop ABS control.)
Problem that
appears on
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF).

1) Turn the starting switch OFF and remove the relay cover.
2) Replace R11 (horn relay) and CUTF relay.
3) Turn the starting switch ON (without starting the engine).
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
The horn does not sound.
(Replace).
2) Disconnect ABS3 and CUTF relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTF (female) and
harness carry out troubleshooting in this state.
2
(Disconnection or defective Resis-
Between ABS3 (female) (8) – CUTF (1) Max. 1 z
contact in connector) tance
Resis-
Between ABS3 (female) (21) – CUTF (2) Max. 1 z
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect ABS3 and CUTF relay.
state Ground fault in wiring 3) Connect T-branch to ABS3 (female) or CUTF (female) and
3 harness carry out troubleshooting in this state.
Between ABS3 (female) (8) – ABS3 Resis-
Min. 1 Mz
(female) (21) tance
2) Disconnect CVF.
4 Hot short in wiring harness 3) Connect T-branch.
Between CVF (1) – CVF (2) Voltage Max. 1 V
2) Disconnect ABS3 and CUTF.
3) Connect T-branch to ABS3 (female) and CUTF (female).
5 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON and OFF.
Between ABS3 (female) (8) + and ABS3 24 V/0 V
Voltage
(female) (21) change
58 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 59
Failure code [DWNDMA] Defective ABS cut-off valve (Front) 1

Action code Failure code Defective ABS cut-off valve (Front)
Trouble
E03 DWNDMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Front) does not match response from the ABS cut-off
trouble valve solenoid switch (Front)
Action of • Stop outputting to ABS cut-off valve relay (Front) (CUTF).
Problem that
appears on
• Ordinary brake operation can be carried out.
machine
• ABS cut-off valve solenoid (front) is turned ON and OFF by turning the ABS cut-off valve relay
(Front) (CUTF) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF) with [DWNDKZ].

2) Replace R11 (horn relay) and CUTF relay.
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
(Replace).
Defective solenoid (Internal 2) Disconnect connector CVF and carry out troubleshooting in this
2 disconnection) of ABS cut-off state.
valve (Front) CVF (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSF.
3) Connect T-branch to connector CVSF and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Front)
Resis-
value in normal OFF: between CVSF (A) – (B) Min. 1 Mz
tance
state
Resis-
ON: between CVSF (A) – (B) Max. 1 z
tance
2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female), CUTF
(female) and CVSF (female) and carry out troubleshooting in
this state.
Resis-
Disconnection in wiring Between ABS3 (female) (2) – CUTF (5) Max. 1 z
tance
harness
4 Resis-
(Disconnection or defective Between CVF (female) (1) – CUTF (3) Max. 1 z
Resis-
Between CVF (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (23) – CVSF (A) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSF (B) Max. 1 z
tance
60 HD465-7E0, HD605-7E0

2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTF
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (23) – CVSF (A) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVF (female) (1) – CUTF (3) and Resis-
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (F) to restore normal state.
(F)
2) Disconnect ABS1 and connect T-branch.
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (23) – ground Voltage
change
HD465-7E0, HD605-7E0 61
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1

Action code Failure code Trouble in ABS cut-off valve (Rear) system
Trouble
E03 DWNEKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Rear) (CUTR).
trouble
• The current flows when the ABS cut-off valve relay (Rear) (CUTR) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR)
controller (Interrupt ABS control)
Problem that
appears on
machine
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR).

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
2) Disconnect ABS3 and CUTR relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
harness carry out troubleshooting in this state.
2
Possible causes Between ABS3 (female) (18) – CUTR (1) Max. 1z
and standard
Between ABS3 (female) (21) – CUTR (2) Max. 1z
state tance
2) Disconnect ABS3 and CUTR relay.
Ground fault in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
3 harness carry out troubleshooting in this state.
Min. 1 Mz
(female) (21) tance
2) Disconnect ABS3 and CUTR.
3) Connect T-branch to ABS3 (female) and CUTR (female).
4 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON-OFF.
Between ABS3 (female) (18) + and ABS3 24 V/0 V
Voltage
(female) (21) change
62 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 63
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1

Action code Failure code Defective ABS cut-off valve (Rear)
Trouble
E03 DWNEMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Rear) does not match response from the ABS cut-off valve
trouble solenoid switch (Rear)
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR).
Problem that
appears on
machine
• ABS cut-off valve solenoid (Rear) is turned ON and OFF by turning the ABS cut-off valve relay
(Rear) (CUTR) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR) with [DWNEKZ].

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
Defective solenoid of ABS 2) Disconnect connector CVR and carry out troubleshooting in
2 cut-off valve (Rear) this state.
(Internal disconnection) CVF (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSR
3) Connect T-branch to connector CVSR and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Rear)
Resis-
value in normal OFF: between CVSR (A) – (B) Min. 1 Mz
tance
state
Resis-
ON: between CVSR (A) – (B) Max. 1 z
tance
2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
(female) and CVSR (female), and carry out troubleshooting in
this state.
Resis-
Disconnection in wiring Between ABS3 (female) (2) – CUTR (5) Max. 1 z
tance
harness
4 Resis-
(Disconnection or defective Between CVR (female) (1) – CUTR (3) Max. 1 z
Resis-
Between CVR (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (17) – CVSR (A) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSR (B) Max. 1 z
tance
64 HD465-7E0, HD605-7E0

2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (17) – CVSR (A) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVR (female) (1) – CUTR (3) and Resis-
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (R) to restore normal state.
(R)
2) Disconnect ABS1.
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (17) – ground Voltage
change
HD465-7E0, HD605-7E0 65

© 2008 KOMATSU
All Rights Reserved
66 HD465-7E0, HD605-7E0
SEN01669-02
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid
valve (Valve keeps operating).................................................................................................................. 4
Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid
valve output circuit ................................................................................................................................... 6
Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve ................. 7
Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid
valve output circuit ................................................................................................................................... 8
Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid
valve (Valve does not operate) ................................................................................................................ 9
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit ...................................................... 10
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit.......................................................... 12
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit.......................................................... 14
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right)
(Valve keeps operating) ......................................................................................................................... 16
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid
valve (right) output circuit....................................................................................................................... 18
HD465-7E0, HD605-7E0 1
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid
valve (right) (Valve does not operate) .................................................................................................... 22
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid
valve (left) (Valve keeps operating)........................................................................................................ 24
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid
valve (left) output circuit ......................................................................................................................... 26
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid
valve (left) (Valve does not operate) ...................................................................................................... 30
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)................................ 31
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) .................................. 32
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)........................................ 33
Failure code [DX21MA] Defective ABS control valve (Front right)................................................................ 34
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) .................................. 35
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)..................................... 36
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) .......................................... 37
Failure code [DX22MA] Defective ABS control valve (Front left) .................................................................. 38
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) ................................ 39
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................................... 40
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ........................................ 41
Failure code [DX23MA] Defective ABS control valve (Rear right) ................................................................ 42
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) .................................. 43
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ..................................... 44
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) .......................................... 45
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................................... 46
Failure code [DX25MA] Defective ABS front wheel system control valve..................................................... 47
Failure code [DX26MA] Defective ABS rear wheel system control valve ..................................................... 47
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 3
Failure code [DX11K4] Trouble in rear brake proportional pressure

reducing solenoid valve (Valve keeps operating) 1
Action code Failure code Trouble in rear brake proportional pressure reducing solenoid
Trouble valve (Valve keeps operating)
E03 DX11K4 (Retarder controller system)
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.
Grounding fault in wiring 3) Connect T-adapter to BRC1 (female).
4 harness
(Contact with ground circuit) Between ground and wiring harness Resis-
between BRC1 (female) (5) – RESW Min. 1 Mz
tance
(female) (A)
2) Connect T-adapter to connector BRC3 (female).
Oil
pressure Voltage Max. 1 V
is ON.
Between BRC3 (16) – (13)
Oil
pressure Voltage 20 – 30 V
is OFF.
4 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5
Failure code [DX11KA] Disconnection in rear brake proportional

pressure reducing solenoid valve output circuit 1
Action code Failure code Disconnection in rear brake proportional pressure reducing sole-
Trouble noid valve output circuit
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
(16) – REVR (female) (1) tance
contact)
Max. 1 z
(13) – REVR (female) (2) tance
2) Connect T-adapter to connector BRC3 (female).
Resis-
tance
6 HD465-7E0, HD605-7E0
Failure code [DX11KB] Short circuit in rear brake proportional pressure

reducing solenoid valve 1
Action code Failure code Short circuit in rear brake proportional pressure reducing solenoid
Trouble valve
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
HD465-7E0, HD605-7E0 7
Failure code [DX11KY] Short circuit in rear wheel proportional pressure

reducing solenoid valve output circuit 1
Action code Failure code Short circuit in rear wheel proportional pressure reducing solenoid
Trouble valve output circuit
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
between BRC3 (female) (16) – REVR Voltage Max. 1 V
(female) (1)
Resis-
tance
8 HD465-7E0, HD605-7E0
Failure code [DX11MA] Trouble in rear wheel proportional pressure

reducing solenoid valve (Valve does not operate) 1
Action code Failure code Trouble in rear wheel proportional pressure reducing solenoid
Trouble valve (Valve does not operate)
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 [DX11K4].
state
HD465-7E0, HD605-7E0 9
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit 1

Action code Failure code Disconnection in hoist EPC valve`output circuit
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 11
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit 1
Action code Failure code Short circuit in hoist EPC valve output 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-
tance
Resis-
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)
Between wiring harness BRC3 (female) (5)
Resis-
– HEPC (female) (1) and wiring harness Min. 1 Mz
tance
BRC3 (female) (13) – HEPC (female) (2)
Resis-
tance
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 13
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit 1
Action code Failure code Short circuit in hoist EPC valve output circuit
Trouble
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-
tance
Resis-
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 power source
between BRC3 (female) (5) – HEPC Voltage Max. 1 V
wiring harness)
(female) (1)
between BRC3 (female) (13) – HEPC Voltage Max. 1 V
(female) (2)
Resis-
tance
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15
Failure code [DX17K4] Trouble in ASR proportional pressure reducing

solenoid valve (right) (Valve keeps operating) 1
Action code Failure code Trouble in ASR proportional pressure reducing solenoid valve
Trouble (right) (Valve keeps operating)
Contents of • Sensor does not respond normally to ASR proportional pressure reducing solenoid valve (right)
trouble OFF command of retarder controller.
Action of
controller
Problem that
machine
Related 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
ASR6 (female) disconnected).
2 Defective sensor 3) Turn starting switch both OFF and ON (Keep ASR switch OFF).
Between ASR6 (male) (1) – ASR6 (male) Resis-
Min. 1 Mz
(2) tance
Possible causes 3 Defective air piping Air piping may be defective. Check it directly.
and standard
value in normal a Turn starting switch OFF and disconnect ASR6 and BRC3, then
state
harness
4 (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
5 harness
Min. 1 Mz
tance
out.)
16 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
Failure code [DX17KA] Disconnection in ASR proportional pressure

reducing solenoid valve (right) output circuit 1
Action code Failure code Disconnection in ASR proportional pressure reducing solenoid
Trouble valve (right) output circuit
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19
Failure code [DX17KB] Ground fault in ASR proportional pressure

Action code Failure code Ground fault in ASR proportional pressure reducing solenoid valve
Trouble (right) output circuit
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21
Failure code [DX17KY] Short circuit in ASR proportional pressure

Action code Failure code Short circuit in ASR proportional pressure reducing solenoid valve
Trouble (right) output circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX17KB].
state
Failure code [DX17MA] Trouble in ASR proportional pressure reducing

solenoid valve (right) (Valve does not operate) 1
Action code Failure code Trouble in ASR proportional pressure reducing solenoid valve
Trouble (right) (Valve does not operate)
Contents of • Sensor does not respond to ASR proportional pressure reducing solenoid valve (right) ON
trouble command of retarder controller.
Action of
controller
Problem that
machine
Related {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],

and standard
value in normal Carry out troubleshooting for failure code [DX17K4].
state
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
Failure code [DX18K4] Trouble in ASR proportional pressure reducing

solenoid valve (left) (Valve keeps operating) 1
Action code Failure code Trouble in ASR proportional pressure reducing solenoid valve (left)
Trouble (Valve keeps operating)
Contents of • Sensor does not respond normally to ASR proportional pressure reducing solenoid valve (left) OFF
trouble command of retarder controller.
Action of
controller
Problem that
machine
Related cm²} – 0.7 (MPa) {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
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
ASR5 (female) disconnected).
2 Defective sensor 3) Turn starting switch both OFF and ON (Keep ASR switch OFF).
Between ASR5 (male) (1) – ASR5 (male) Resis-
Min. 1 Mz
(2) tance
Possible causes 3 Defective air piping Air piping may be defective. Check it directly.
and standard
value in normal a Turn starting switch OFF and disconnect ASR5 and BRC3, then
state
harness
4 (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
5 harness
Min. 1 Mz
tance
out.)
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
Failure code [DX18KA] Disconnection in ASR proportional pressure

reducing solenoid valve (left) output circuit 1
Action code Failure code Disconnection in ASR proportional pressure reducing solenoid
Trouble valve (left) output circuit
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 27
Failure code [DX18KB] Ground fault in ASR proportional pressure

Action code Failure code Ground fault in ASR proportional pressure reducing solenoid valve
Trouble (left) output circuit
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 29
Failure code [DX18KY] Short circuit in ASR proportional pressure

Action code Failure code Short circuit in ASR proportional pressure reducing solenoid valve
Trouble (left) output circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX18KB].
state
Failure code [DX18MA] Trouble in ASR proportional pressure reducing

solenoid valve (left) (Valve does not operate) 1
Action code Failure code Trouble in ASR proportional pressure reducing solenoid valve (left)
Trouble (Valve does not operate)
Contents of • Sensor does not respond to ASR proportional pressure reducing solenoid valve (left) ON command
trouble of retarder controller.
Action of
controller
Problem that
machine
Related {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 (left) has electrical trouble, code [DX18KA],

and standard
value in normal Carry out troubleshooting for failure code [DX18K4].
state
30 HD465-7E0, HD605-7E0
Failure code [DX21KA] Disconnection in ABS control valve output

circuit (Front right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front right)
Trouble
E03 DX21KA (ABS controller system)
Contents of
• No current flows when the signal is output to the ABS control valve (Front right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
(Code: 43309, output current (0 – 1000 (mA))
information
• No signal is output to ABS control valve solenoid until starting switch is turned OFF.

2) Disconnect connector ABSFR.
Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSFR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFR and ABS3 and
value in normal harness carry out troubleshooting in this state.
state 2
Between ABS3 (female) (3) and ABSFR (2) Max. 1 z
Resis-
Between ABS3 (female) (6) and ABSFR (1) Max. 1 z
tance
10 – 30 z
(female) (3) terminals tance
HD465-7E0, HD605-7E0 31
Failure code [DX21KB] Ground fault in ABS control valve output circuit
(Front right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front right)
Trouble
E03 DX21KB (ABS controller system)
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front right) solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSFR.
Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSFR and ABS3.
value in normal Ground fault in wiring 3) Connect the T-branch to connector ABS3 and carry out trouble-
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSFR and ABS3 being disconnected).
Resis-
Between ABS3 (female) (6) and ground Max. 1 Mz
tance
10 – 30 z
32 HD465-7E0, HD605-7E0
Failure code [DX21KY] Hot short in ABS control valve output circuit
(Front right) 1
Action code Failure code Hot short in ABS control valve output circuit (Front right)
Trouble
E03 DX21KY (Transmission controller system)
Contents of
• Abnormal current flows when no signal is output to ABS control valve solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connectors ABS3 and ABSFR.
Hot short circuit in wiring 3) Connect the T-branch to ABS3.
1 harness (With connector ABSFR being disconnected).
Possible causes (Contact with 24-V circuit)
and standard 4) Carry out troubleshooting with the starting switch ON.
value in normal Between ABS3 (female) (6) and ground Voltage Max. 1 V
10 – 30 z
HD465-7E0, HD605-7E0 33
Failure code [DX21MA] Defective ABS control valve (Front right) 1

Action code Failure code Defective ABS control valve (Front right)
Trouble
E03 DX21MA (ABS controller system)
Contents of • Command to ABS control valve (Front right) does not match response from ABS control valve pres-
trouble sure sensor.
Problem that
appears on
• Troubleshooting for ABS control valve (Front right) solenoid circuit is carried out with [DX21KA],
[DX21KB] and [DX21KY].
Related • Troubleshooting for ABS control valve (Front right) pressure sensor is carried out with [DHU6KX].
information • Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.

If failure codes [DX21KA], [DX21KB], [DX21KY] and [DHU6KX] are displayed, carry out trouble-
1
Possible causes shooting for them.
and standard Defective ABS control valve Main pressure variable valve may be damaged mechanically.
2
value in normal (Front right) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be damaged. Check it directly.
If causes 1 – 3 are not detected, ABS controller may be defective.
4 Defective ABS controller
34 HD465-7E0, HD605-7E0

circuit (Front left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Front left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSFL.
Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
1 solenoid bleshooting with the starting switch OFF.
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSFL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFL and ABS3, and
value in normal harness carry out troubleshooting with the starting switch OFF.
state 2
(Disconnection or defective Wiring harness between ABS3 (female) (3) Resis-
Max. 1 z
contact in connector) – ABSFL (2) tance
Max. 1 z
– ABSFL (1) tance
10 – 30 z
– ABS3 (female) (3) tance
HD465-7E0, HD605-7E0 35
(Front left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front left) solenoid circuit.
trouble
Problem that
appears on
Related
information

2) Disconnect connector ABSFL.
Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSFL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSFL and ABS3 disconnected)
Resis-
tance
10 – 30 z
– ABS3 (female) (3) terminal tance
36 HD465-7E0, HD605-7E0
(Front left) 1
Action code Failure code Hot short in ABS control valve output circuit (Front left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

2) Disconnect connectors ABS3 and ABSFL.
Hot short circuit in wiring 3) Connect T-branch to connector ABS3.
1 harness (With connector ABSFL being disconnected)
Possible causes (Contact with 24V circuit)
and standard 4) Turn starting switch ON and carry out troubleshooting.
10 – 30 z
HD465-7E0, HD605-7E0 37
Failure code [DX22MA] Defective ABS control valve (Front left) 1

Action code Failure code Defective ABS control valve (Front left)
Trouble
Contents of • Command to ABS control valve (Front left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Front left) solenoid circuit is carried out with [DX22KA],
Related • Troubleshooting for ABS control valve (Front left) pressure sensor is carried out with [DHU7KX].
information • Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.

1
2
value in normal (Front left) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
(Since trouble is in system, troubleshooting is disabled.)
38 HD465-7E0, HD605-7E0

circuit (Rear right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear right)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rear right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRR.
Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSRR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRR and ABS3, and
state 2
Max. 1 z
contact in connector) – ABSRR (2) tance
Max. 1 z
– ABSRR (1) tance
10 – 30 z
HD465-7E0, HD605-7E0 39
(Rear right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear right)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear right) solenoid circuit.
trouble
Problem that
appears on
Related
information

2) Disconnect connector ABSRR.
Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSRR and ABS3.
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSRR and ABS3 being disconnected)
Resis-
tance
10 – 30 z
40 HD465-7E0, HD605-7E0
(Rear right) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear right)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

2) Disconnect connectors ABS3 and ABSRR.
1 harness (With connector ABSRR being disconnected)
Possible causes (Contact with 24-V circuit)
and standard 4) Carry out troubleshooting with the starting switch turned ON.
10 – 30 z
HD465-7E0, HD605-7E0 41
Failure code [DX23MA] Defective ABS control valve (Rear right) 1

Action code Failure code Defective ABS control valve (Rear right)
Trouble
Contents of • Command to ABS control valve (Rear right) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear right) solenoid circuit is carried out with [DX23KA],
Related • Troubleshooting for ABS control valve (Rear right) pressure sensor is carried out with [DHU8KX].
information • Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear right) Check it directly.
42 HD465-7E0, HD605-7E0

circuit (Rear left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rea left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRL.
Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSRL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRL and ABS3, and
state 2
Max. 1 z
contact in connector) – ABSRL (2) tance
Max. 1 z
– ABSRL (1) tance
10 – 30 z
HD465-7E0, HD605-7E0 43
(Rear left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear left) solenoid circuit.
trouble
Problem that
appears on
Related
information

2) Disconnect connector ABSRL.
Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSRL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSFL and ABS3 being disconnected)
Resis-
tance
10 – 30 z
44 HD465-7E0, HD605-7E0
(Rear left) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

2) Disconnect connectors ABS3 and ABSRL.
1 harness (With connector ABSRL being disconnected)
Possible causes (Contact with 24-V circuit) 4) Turn starting switch ON and carry out troubleshooting.
and standard
Between ABS3 (female) (36) and chassis
value in normal Voltage Max. 1 V
ground
state
10 – 30 z
HD465-7E0, HD605-7E0 45
Failure code [DX24MA] Defective ABS control valve (Rear left) 1

Action code Failure code Defective ABS control valve (Rear left)
Trouble
Contents of • Command to ABS control valve (Rear left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DX24KA],
Related • Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DHU9KX].
information • Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear left) Check it directly.
46 HD465-7E0, HD605-7E0
Failure code [DX25MA] Defective ABS front wheel system control valve 1
Action code Failure code Defective ABS front wheel system control valve
Trouble
• Command to ABS control valve (Front) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Front right or front left)
Action of • Stop outputting to ABS control valve (Front) solenoid circuit.
Problem that
appears on
• Check for front right or front left according to failure codes [DX21MA] (front right) and [DX22MA]
Related
(front left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX21MA] or [DX22MA].
state
Failure code [DX26MA] Defective ABS rear wheel system control valve 1
Action code Failure code Defective ABS rear wheel system control valve
Trouble
• Command to ABS control valve (Rear) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Rear right or rear left)
Action of • Stop outputting to ABS control valve (Rear) solenoid circuit.
Problem that
appears on
• Check for rear right or rear left according to failure codes [DX23MA] (rear right) and [DX24MA] (rear
Related
left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX23MA] or [DX24MA].
state
HD465-7E0, HD605-7E0 47

© 2007 KOMATSU
All Rights Reserved
48 HD465-7E0, HD605-7E0
SEN01670-02
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ............................................. 3
Failure code [DXH1KB] (Lock-up 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
HD465-7E0, HD605-7E0 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
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) (Blow-by pressure: High error) .................... 60
(Exhaust gas temperature (F): Abnormal heat) ..................................................................................... 62
(Exhaust gas temperature (F): Overheat) .............................................................................................. 64
(Exhaust gas temperature (R): abnormal heat) ..................................................................................... 66
(Exhaust gas temperature (R): Overheat).............................................................................................. 68
2 HD465-7E0, HD605-7E0
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 • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
information • 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.

solenoid tance
Min. 1 Mz
ground tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and L/U.PS
value in normal Disconnection in wiring (CN16) (female).
state harness
(Disconnection or improper Max. 1 z
contact)
Max. 1 z
3
controller Resis-
tance
HD465-7E0, HD605-7E0 3
Failure code [DXH1KB] (Lock-up 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.
Problem that
• Lockup system is kept OFF.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
Related
information • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).

solenoid tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and L/U.PS (CN16).
Possible causes
3) Connect T-adapter to ATC3 (female).
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (35) – L/U.PS Min. 1 Mz
2 tance
or contact between har- (CN16) (female) (1)
nesses) Between wiring harness from ATC3 (female)
(35) – L/U. PS (CN16) (female) (1) and wir- Resis-
Min. 1 Mz
ing harness from ATC3 (female) (23) –L/ tance
U.PS (CN16) (female) (2)
3
controller Resis-
tance
4 HD465-7E0, HD605-7E0
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.
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
information • Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA))

solenoid tance
Min. 1 Mz
ground tance
and standard 2) Disconnect connectors ATC3 and L/U.PS (CN16).
value in normal 3) Connect T-adapter to ATC3 (female).
2
between ATC3 (female) (35) – L/U.PS Voltage Max. 1 V
(CN16) (female) (1)
3
controller Resis-
tance
HD465-7E0, HD605-7E0 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 • Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).

Resis-
tance
Min. 1 Mz
ground tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and H.PS
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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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
information • Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA)).

Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and H.PS (CN19).
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness between
Resis-
state (Contact with ground circuit ATC3 (female) (26) – H.PS (CN19) (female) Min. 1 Mz
2 tance
or contact between har- (1)
(26) – H.PS (CN19) (female) (1) and wiring Resis-
Min. 1 Mz
harness from ATC3 (female) (13) – H.PS tance
(CN19) (female) (2)
3
controller Resis-
tance
8 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
and standard 2) Disconnect connectors ATC3 and H.PS (CN19).
2
between ATC3 (female) (26) – H.PS (CN19) Voltage Max. 1V
(female) (1)
3
controller Resis-
tance
10 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 11
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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.

Resis-
tance
Min. 1 Mz
ground tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and L.PS
state harness
contact)
Max. 1 z
3
5 – 15 z
– (13) tance
14 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and L.PS (CN17).
Possible causes
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (6) – L.PS (CN17) Min. 1 Mz
2 tance
or contact between har- (female) (1)
(6) – L.PS (CN17) (female) (1) and wiring Resis-
Min. 1 Mz
harness from ATC3 (female) (13) – L.PS tance
(CN17) (female) (2)
3
controller Resis-
tance
16 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
and standard 2) Disconnect connectors ATC3 and L.PS (CN17).
2
between ATC3 (female) (6) – L.PS (CN17) Voltage Max. 1 V
(female) (1)
Defective transmission 2) Connect T-adapter ATC3 (female).
3
controller Resis-
tance
18 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 19
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
Possible causes
and standard
Disconnection in wiring 2) Connect T-adapter to ATC3 (female) and 1.PS (CN6) (female).
value in normal
state harness Wiring harness between ATC3 (female) (36) Resis-
2 Max. 1 z
(Disconnection or improper – 1. PS (CN6) (female) (1) tance
Max. 1 z
– 1. PS (CN6) (female) (2) tance
Defective transmission 2) Connect T-adapter to ATC3 (female).
3
controller Resis-
tance
22 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors to ATC3 and 1.PS (CN6).
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness between
Resis-
state (Contact with ground circuit ATC3 (female) (36) – 1.PS (CN6) (female) Min. 1 Mz
2 tance
or contact between har- (1)
(36) – 1.PS (CN6) (female) (1) and wiring Resis-
Min. 1 Mz
harness from ATC3 (female) (3) – 1.PS tance
(CN6) (female) (2)
3
controller Resis-
tance
24 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
and standard 2) Disconnect connectors ATC3 and 1.PS (CN6).
2
between ATC3 (female) (36) – 1.PS (CN6) Voltage Max. 1 V
(female) (1)
3
controller Resis-
tance
26 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 27
28 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and 2.PS
state harness
contact)
Max. 1 z
3
controller Resis-
tance
30 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 31
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)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

Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and 2.PS (CN8).
Possible causes
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (5) – 2.PS (CN8) Min. 1 Mz
2 tance
Min. 1 Mz
(CN8) (female) (2)
3
controller Resis-
tance
32 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2
(a contact with 24V circuit)
(female) (1)
3
controller Resis-
tance
34 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 35
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
and standard 2) Disconnect T-adapter connectors to ATC3 (female) and 3.PS
value in normal Disconnection in wiring (CN10) (male).
state harness
contact)
Max. 1 z
3
controller Resis-
tance
38 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 39
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)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

Resis-
tance
Min. 1 Mz
ground tance
Possible causes
and standard
Resis-
2 tance
Min. 1 Mz
(CN10) (female) (2)
3
controller Resis-
tance
40 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2
(female) (1)
3
controller Resis-
tance
42 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 43
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and R.PS
state harness
contact)
Max. 1 z
3
controller Resis-
tance
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and R.PS (CN12).
Possible causes
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (25) – R.PS (CN12) Min. 1 Mz
2 tance
(25) – R.PS (CN12) (female) (1) and wiring Resis-
Min. 1 Mz
harness from ATC3 (female) (23) – R.PS tance
(CN12) (female) (2)
3
controller Resis-
tance
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

2) Connect T-adapter to connector CN12 (male).
Resis-
1 Defective R clutch ECMV Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN12 (male) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Disconnect connectors ATC3 and CN12.
2
between ATC3 (female) (25) – CN12 Voltage Max. 1 V
(female) (1)
3
controller Resis-
tance
50 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Min. 1 Mz
ground tance
Possible causes
and standard
Disconnection in wiring 2) Connect T-adapter to ATC3 (female) and 4.PS (CN14) (female).
value in normal
state harness Wiring harness between ATC3 (female) (16) Resis-
2 Max. 1 z
(Disconnection or defective – 4.PS (CN14) (female) (1) tance
Max. 1 z
3
5 – 15 z
– (3) tance
52 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
Possible causes
and standard
Resis-
2 tance
Min. 1 Mz
(CN14) (female) (2)
3
controller Resis-
tance
54 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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

Resis-
tance
Min. 1 Mz
ground tance
2
(female) (1)
3
controller Resis-
tance
56 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 57
58 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 59
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”)

(Blow-by pressure: High error) 1
Action code Failure code Blow-by pressure: High error
Trouble
— F@BBZL (VHMS controller system) (Display: PLM)
Contents of
• Blow-by pressure exceeded 12.9 kPa {1,320 mmH2O}.
trouble
Action of
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The LED of the VHMS controller displays “n3” o “38”
• The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
Related
function (Code: 42801 BLOWBY PRESS)
information
• If failure code: DHE5KB (Blow-by pressure sensor: Short circuit) or failure code: DHE5KY (Blow-by
pressure sensor: Short circuit with power supply line) is displayed, troubleshooting for it is per-
formed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Check the engine for abnormality. Correct, if any.
1 Blow-by pressure increases
Possible causes Check the breather hose for clogging, bend, or break. If any, repair it.
and standard Defective blow-by pressure
value in normal 2 sensor Check the blow-by pressure sensor for abnormality. Replace, if any.
state
If the above items 1 and 2 is normal, the VHMS controller may be
3 defective. (Troubleshooting cannot be carried out since the defect
controller
is in the machine monitor.)
60 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 61

(Exhaust gas temperature (F): Abnormal heat) 1
Action code Failure code Exhaust gas temperature (F): Abnormal heat
Trouble
— F@BYNR (VHMS controller system) (Display: PLM)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas
Contents of temperature beyond the limit line 2 was detected min. 10 seconds.
trouble (Exhaust gas temperature limit line 2: Straight line between 750°C at rated output speed at mini-
mum and 800°C at max. torque speed at maximum)
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Short circuit) is displayed, troubleshooting for it is
performed first.

Exhaust gas temperature at
the engine front side abnor-
1 Check the engine for abnormality. Correct, if any.
mally rises.
(When the system is normal)
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal Exhaust gas
state HM-CN2A Voltage
temperature
2 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
62 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 63

(Exhaust gas temperature (F): Overheat) 1
Action code Failure code Exhaust gas temperature (F): Overheat
Trouble
— F@BYNS (VHMS controller system) (Display: PLM)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas tem-
Contents of perature beyond the limit line 1 was detected min. 1 seconds.
trouble (Exhaust gas temperature limit line 1: Straight line between 700°C at rated output speed at minimum
and 750°C at max. torque speed at maximum)
Action of
controller
Problem that
machine
• The LED of the VHMS controller displays “n3” o “61”
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Short circuit) is displayed, troubleshooting for it is
performed first.

the engine front side abnor-
mally rises.
(When the system is normal)
temperature
2 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
64 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 65

(Exhaust gas temperature (R): abnormal heat) 1
Action code Failure code Exhaust gas temperature (R): Abnormal heat
Trouble
— F@BZNR (VHMS controller system) (Display: PLM)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Contents of perature beyond the limit line 2 was detected min. 10 seconds.
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Short circuit) is displayed, troubleshooting for it is
performed first.

increases abnormally. (When
the system is normal)
temperature
2 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
66 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 67

(Exhaust gas temperature (R): Overheat) 1
Action code Failure code Exhaust gas temperature (R): Overheat
Trouble
— F@BZNS (VHMS controller system) (Display: PLM)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Contents of perature beyond the limit line 1 was detected min. 1 second.
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Short circuit) is displayed, troubleshooting for it is
performed first.

increases abnormally. (When
the system is normal)
temperature
2 50 – 100°C 1.0 – 1.6 V
controller
300 – 400°C 2.1 – 2.7 V
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V
68 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 69

© 2008 KOMATSU
All Rights Reserved
70 HD465-7E0, HD605-7E0
SEN01671-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
E-6 Alarm buzzer does not stop sounding .................................................................................................... 18
section do not display properly .............................................................................................................. 20
E-8 A selection of the display in character display section cannot be changed............................................ 21
E-9 Power mode selecting function does not operate properly .................................................................... 24
E-10 AISS function does not operate properly.............................................................................................. 25
E-11 Seat belt caution lamp does not display properly ................................................................................. 26
HD465-7E0, HD605-7E0 1
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly ................................................. 27
E-13 Night illumination (lighting) does not work properly .............................................................................. 30
E-14 Emergency steering does not operate.................................................................................................. 42
E-15 Hoist lever does not operate normally .................................................................................................. 48
E-16 Electric priming pump does not operate or does not stop automatically .............................................. 50
2 HD465-7E0, HD605-7E0
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".
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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, R38, E02A, and starting switch ter-
minals.
Harness between starting switch (terminal Resis-
C) – R38 (female) (3) 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, R38, E02A, and starting switch ter-
minals.
Hot short of wiring harness Between ground and wiring harness
10
(a 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
(15), 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
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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
Resis-
3 (internal disconnection) Between heater inlet terminal – ground Max. 1 z
tance
(internal resistance: 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 HD465-7E0, HD605-7E0

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)
HD465-7E0, HD605-7E0 9
10 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 (1), (20) When the fuse BT2 (1), (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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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.
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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).
value in normal Short circuit of harness
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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 17
E-6 Alarm buzzer does not stop sounding 1

When starting switch is turned ON, centralized warning lamp lights up and alarm buzzer does not stop
Trouble
sounding.
Related • Since causes 2 – 7 are alarms turned ON to avoid danger in operation, they are turned OFF if oper-
information ational problem is solved.

• When trouble is detected, centralized warning lamp lights up
and alarm buzzer sounds.
1 Trouble detection (Note: Some troubles do not turn lamp/buzzer ON.)
• In this case, perform troubleshooting for displayed code (check
trouble record, too).
• While engine is running and parking brake switch is in "Park"
position, if gear shift lever is set in position other than "N", cen-
2 Parking brake drag warning tralized warning lamp lights up and alarm buzzer sounds.
• If parking brake switch is set in "Travel" position or gear shift
lever is set in "N" position, alarm is turned OFF.
• If travel speed exceeds set speed or engine speed increases
abnormally, centralized warning lamp lights up and alarm buzzer
3 Overrun warning sounds.
• If travel speed lowers below set speed and engine speed
decreases to normal range, alarm is turned OFF.
• While engine is running, if body is raised (body pilot lamp in
machine monitor is lighting up) or gear shift lever is set in posi-
tion other than "N" with parking brake switch in "Travel" position,
4 Body up warning
centralized warning lamp lights up and alarm buzzer sounds.
• If body is lowered or parking brake switch is set in "Park" posi-
tion or gear shift lever is set in "N" position, alarm is turned OFF.
• While gear shift lever is not in "N" position, if starting switch is
Possible causes
turned from OFF position to ON, centralized warning lamp lights
and standard 5 Neutral safety warning
up and alarm buzzer sounds.
value in normal
• If gear shift lever is set in "N" position, alarm is turned OFF.
state
• If this function is set and body is raised (body pilot lamp in
Warning by body up caution machine monitor is lighting up) while the engine is running, cen-
6
function (if equipped) tralized warning lamp lights up and alarm buzzer sounds.
• If body is lowered, alarm is turned OFF.
• While gear shift lever is not in "N" position, if engine start signal
(key switch terminal C) is detected, centralized warning lamp
Warning for start in position
7 lights up and alarm buzzer sounds.
other than neutral
• If gear shift lever is set in "N" position or engine start signal is
turned OFF, alarm is turned OFF.
• When engine is started, if accumulator oil pressure is low,
retarder caution lamp (accumulator oil pressure reduction detec-
tion) and centralized warning lamp light up and alarm buzzer
Retarder oil pressure reduc-
8 sounds.
tion detection
(Reference: If 30 seconds pass, [2G42ZG] or [2G43ZG] and
[DHU2KX] or [DHU3KX] failure codes are turned ON.)
• Check retarder hydraulic circuit (accumulator oil pressure).
• If initialization is not performed normally after controller is
replaced, centralized warning lamp lights up and alarm buzzer
9 Defective initialization
sounds.
• Perform initialization correctly.
• If above causes are not detected, machine monitor or controller
Defective machine monitor
10 may be defective. (Since trouble is in system, troubleshooting
or controller
cannot be performed.)
18 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19

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).
20 HD465-7E0, HD605-7E0
E-8 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
HD465-7E0, HD605-7E0 21
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
22 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 23
E-9 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
24 HD465-7E0, HD605-7E0
E-10 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
HD465-7E0, HD605-7E0 25
E-11 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-
(11) – SBS (female) (2) tance
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
26 HD465-7E0, HD605-7E0
E-12 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
HD465-7E0, HD605-7E0 27

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
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
(Contact with ground circuit) Between ground and wiring harness
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)
28 HD465-7E0, HD605-7E0

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)
HD465-7E0, HD605-7E0 29
E-13 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
(2) 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
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
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 (right and left) 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)
32 HD465-7E0, HD605-7E0
Trouble (4) Right small lamp (clearance lamp) does not "right" light up.
Related • Carry out following troubleshooting when left small lamp and headlamps (right and left) 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)
HD465-7E0, HD605-7E0 33
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)
34 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 35
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 (R11).
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) (3) (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) (3) (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
36 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 37
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.
38 HD465-7E0, HD605-7E0
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)
HD465-7E0, HD605-7E0 39
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
value in normal Disconnection in wiring (female).
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)
40 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 41
E-14 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.
Between motor terminal M and ground Voltage 20 – 30 V
Possible causes Defective emergency
and standard 4 1) Turn starting switch OFF.
steering motor
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
42 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 43
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
44 HD465-7E0, HD605-7E0

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.)
HD465-7E0, HD605-7E0 45
46 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 47
E-15 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.)
48 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 49
E-16 Electric priming pump does not operate or does not stop
automatically 1
Trouble • Electric priming pump does not operate or does not stop automatically
Related
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
If the fuse is burn, circuit probably has ground fault. (Check cause No.
2 Defective EPF of fuse
5.)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it and
harness (Power supply carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring
or defective contact in Between EPTS (1) – (2) Voltage 20 – 30 V
connector)
a Prepare with battery ground cable disconnected, then connect battery
and turn electric priming pump ON and carry out troubleshooting.
harness (Drive power • Lamp blinks but stops in about 5 seconds.
supply system) Between EP (1) – (2) Voltage 20 – 30 V
4
(Disconnection in wiring a Prepare with battery ground cable disconnected, then carry out trou-
or defective contact in bleshooting without reconnecting (since power supply is unswitched).
connector)
Resis-
Between EPTS (female) (2) – ground Max. 1 z
tance
Possible causes a Prepare with battery ground cable disconnected, then carry out trou-
and standard bleshooting without reconnecting (since power supply is unswitched).
value in normal Wiring harness between EPTS(female) (1) – EPF Resis-
state Min. 1 Mz
(female) (1) and ground tance
Wiring harness between EPTS (female) (3) – EP Resis-
5 harness (Contact with Min. 1 Mz
GND circuit)
Wiring harness between EPTS (female) (4) – EP Resis-
Min. 1 Mz
Resis-
Between EP (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect battery
and turn electric priming pump ON and carry out troubleshooting.
Between EPTS (3) – (4) Voltage 20 – 30 V
Defective electric prim-
ing pump switch (Mal- • Lamp blinks but output voltage is improper.
6 • Results of troubleshooting steps 1 – 4 are normal and lamp does not
function or automatic
stop failure) blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric
7 a If pump is overloaded, power supply is turned OFF automatically to
priming pump
protect circuit (Priming switch is reset automatically).
50 HD465-7E0, HD605-7E0
Cause Standard value in normalcy and references for troubleshooting

a Prepare with battery ground cable disconnected, then carry out trou-
bleshooting without reconnecting (since power supply is unswitched).
Possible causes
Resis-
and standard Between EP (male) (1) – (2) 1–3z
tance
value in normal 8 Trouble in electric priming
state pump Resis-
Between EP (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EP (male) (2) – pump body Min. 1 Mz
tance
HD465-7E0, HD605-7E0 51

© 2009 KOMATSU
All Rights Reserved
52 HD465-7E0, HD605-7E0
SEN01672-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0

• 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
Hi Lo 1st 2nd 3rd 4th R
R q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Table 1
Operated clutches
R q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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
R q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
Table 1
Operated clutches
R q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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: 4.4 ± 0.15 MPa {45 ± 1.5 kg/
value in normal
state 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 HD465-7E0, HD605-7E0
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: 4.4 ± 0.15 MPa {45 ± 1.5 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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 25

© 2007 KOMATSU
All Rights Reserved
26 HD465-7E0, HD605-7E0
SEN01673-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 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 ............................................................................................................................. 10
S-3 Engine does not pick up smoothly.......................................................................................................... 14
S-4 Engine stops during operation................................................................................................................ 15
S-5 Engine does not rotate smoothly ............................................................................................................ 16
S-6 Engine lack output (or lacks power) ....................................................................................................... 17
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 18
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 20
S-9 Oil becomes dirty quickly........................................................................................................................ 21
S-10 Fuel consumption is excessive............................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 23
S-12 Oil pressure drops ................................................................................................................................ 24
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 26
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 28
HD465-7E0, HD605-7E0 1
S-15 Abnormal noise is made ....................................................................................................................... 29

S-16 Vibration is excessive ........................................................................................................................... 30
S-17 Air cannot be bled from fuel circuit ....................................................................................................... 32
2 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 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 HD465-7E0, HD605-7E0
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.
HD465-7E0, HD605-7E0 7
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)
Leaking or clogged fuel piping or entry of air

q Insufficient supply of fuel
Clogged air breather hole of fuel tank cap

Insufficient intake of air
Defective contact of valve and vale seat

q
Defective alternator (generator section)

Defective alternator (regulator section)
Stuck or seized supply pump plunger
q Improper selection of fuel
Defective intake air heater system

Coolant in exhaust pipe
Defective or deteriorated battery

q
Clogged feed pump gauze filter

a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element
Clogged fuel filter element

nizes the fuel injection timing electrically. Accord-
Worn piston ring, cylinder

ingly, even if the starting operation is carried out, the
engine may not start until the crankshaft revolves 2
Defective injector
turns at maximum. This phenomenon does not indi-
cate a trouble, however
Confirm recent repair history

Degree of use of
machine Operated for long period E E E E E
Became worse gradually Q 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
indicate 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 Q w
While engine is When air bleeding plug of fuel filter is removed, fuel does not
flow out w w
rotated with starting
motor When spill hose from injector is disconnected, little fuel spills w
Check items
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

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1) q
Compression pressure is low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*2)" 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 Yes q

while 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
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 HD465-7E0, HD605-7E0
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and see if the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent,
however, it is not a problem.
*2: Displayed failure codes: [CA559] and [CA2249]
HD465-7E0, HD605-7E0 9
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Cracked EGR cooler (Coolant in exhaust pipe)
Defective starting motor (safety relay section)

q Seized internal parts of engine
o See "S-4 Engine stops during operation"
Defective connection of battery terminal
Defective starting motor (motor section)

q Water hammer caused by coolant which entered cylinder
q Defective electrical system
Defective starting circuit wiring

q Trouble in power train
o Carry out troubleshooting on H-mode
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of use of
Operated for long period E 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 Q 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
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
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
q
on E-mode
OFF, connect cables, starts
turn starting switch ON,
and carry out trouble- When terminals B and C at safety relay outlet are connected, engine
q
shooting starts
Even if terminals B and C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
10 HD465-7E0, HD605-7E0

HD465-7E0, HD605-7E0 11
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
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
Air breather hole of fuel tank cap is clogged Q 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 Q Q w Q
While engine is not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel Q w w w w Q
spills

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]

12 HD465-7E0, HD605-7E0
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
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
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
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting

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
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
HD465-7E0, HD605-7E0 13
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

EGR valve stuck open

q

(There is much EGR gas and intake of air is insufficient)
Improper valve clearance

Stuck EGR valve
Degree of use of
machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly became worse Q 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

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

Carry out troubleshooting according to supply pump low pressure "Rail Press (Very) Low
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
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

14 HD465-7E0, HD605-7E0
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 power train
Broken or seized piston or connecting rod


Broken or seized crankshaft bearing
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 Q Q
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
Press (Very) Low Error (*1)" indicated by code q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)

q
is removed
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
HD465-7E0, HD605-7E0 15
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

q Defective EGR valve
Defective Ne speed sensor or wiring harness

q Defective bypass valve

Low setting of low idle speed

Malfunction of bypass valve
Malfunction of EGR valve

Q Q 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 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
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by q
code
Troubleshooting

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 (*3)" indicated by
q
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated
q
by code
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add

*2: Displayed failure code [CA1628] and [CA1629]
*3: Displayed failure code [CA689]
*4: Displayed failure code [CA778]
16 HD465-7E0, HD605-7E0
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)"

q Control by controller in derate mode
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
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 "Chg 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
*1: Displayed failure code [CA559] and [CA2249] Remedy

HD465-7E0, HD605-7E0 17
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
q Insufficient intake of air
Leakage of air between turbocharger and cylinder head

q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

q Overheating

o See "S-14 Coolant temperature becomes too high

(Overheating)"
Control by controller in derate mode

q
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector

q EGR valve stuck open
(There is much EGR gas and intake of air is insuffi-
Stuck EGR valve

cient)
q Clogged EGR gas pressure piping
(Exhaust gas is mixed in intake air during accelera-
tion and deceleration)
Suddenly became black w Q 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
Immediately after engine is started, temperature of exhaust manifold of a cylinder is
low Q w
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 Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by
code q
Troubleshooting

When muffler is removed, exhaust gas color improves q
Carry out troubleshooting according to supply pump low pressure "Rail Press (Very)
Low Error (*2)" indicated by code q q
not change q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*3)"
indicated by code q
Check with monitoring function (*4). q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
18 HD465-7E0, HD605-7E0

*4: 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).
HD465-7E0, HD605-7E0 19
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
Oil leakage from EGR valve stem

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 E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently Q 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 Q w w
Excessive 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
Play of turbocharger shaft is excessive q q
Troubleshooting
Exhaust port of EGR valve is dirty with oil 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
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 HD465-7E0, HD605-7E0
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 end
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

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Questions

Non-specified fuel is used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed) w Q
There are metal particles in oil drained from oil filter Q Q w

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 Q
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Exhaust port of EGR valve is dirty with oil 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
Clean
Remedy
—
HD465-7E0, HD605-7E0 21
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
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
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
Correct
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.
22 HD465-7E0, HD605-7E0
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
—
HD465-7E0, HD605-7E0 23
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
q Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed.
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E 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 Q
Indicates pressure drop at low, high idle Q w w w Q Q Q
Oil pressure monitor
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil lever drop w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w 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 Q
There are metal particles in oil filter q

Inspect oil pan strainer and pipe directly q q
q
Troubleshooting
Oil pump is heavy to rotate or it has play

See S-13
Valve spring of oil pump relief valve is fatigued or damaged q

Inspect oil filter directly q
Relief valve of EGR oil pump is damaged or oil leaks through it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)"
q
indicated by code
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
24 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 25
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

coolant"
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, water drops from muffler Q Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles w Q
Check items
come out or coolant spurts back

Exhaust gas is white Q 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
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
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 thermostat cover 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
Correct
Correct
Remedy
26 HD465-7E0, HD605-7E0

HD465-7E0, HD605-7E0 27
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too Causes
high
Rise of power train oil temperature on applicable machine side

q Lack of cooling air (deformation or damage of fan)

q Drop in heat dissipation efficiency
q Trouble in coolant circulation system
q Rise of oil temperature in power train
External leakage of coolant from EGR cooler
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 Q w Q
Overheating
Has continued at low level 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) Q 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
Dirt and mud are accumulated in radiator shroud and undercover on applicable
Check items
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
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)
Inspect EGR cooler for coolant leakage q

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
on H-mode
Temperature difference between upper and lower tanks of radiator is slight q

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
Correct
Remedy
—
Add
28 HD465-7E0, HD605-7E0
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
Excessive wear of piston ring or cylinder liner

while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not indi-
Removed or seized gear train bushing

cate abnormality, however
Cracked or leaking EGR gas piping

a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little larger
Improper gear train backlash

for up to about 5 seconds. This does not indicate abnor-
Clogged or seized injector

mality, however
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 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 EGR gas piping 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 w Q

low
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

Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
q q
not 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
Correct
Correct
Correct
Adjust
Remedy
HD465-7E0, HD605-7E0 29
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
Improper injection timing

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
Confirm with monitoring function on applicable machine side 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
Adjust
Remedy
30 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 31
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of Operated for long period E E

machine
Non-specified fuel is being used Q Q
Fuel tank cap breather hole is clogged Q w
Check items
Switch lamp does not blink w w Q

When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
Q Q w w w Q Q
of hose soon
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-16) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Add
Remedy
32 HD465-7E0, HD605-7E0
Note 1: Check of air bleeding piping for clogging
q Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
q Remove air bleeding piping (2) and blow compressed air against its both ends to check for clogging.
HD465-7E0, HD605-7E0 33

© 2009 KOMATSU
All Rights Reserved
34 HD465-7E0, HD605-7E0
SEN02483-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 10
HD465-7E0, HD605-7E0 1
SEN02483-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools [*1] : This mark shows that instructions or precau-
N: Tools newly developed for this tions for parts installation work are given in
model. They have a new part num- "Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were 4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] ••• etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
k
from Komatsu Ltd. (i.e. tools to be
made locally).
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 HD465-7E0, HD605-7E0
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] ••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be : Amount of oil or coolant to be replenished
made locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
HD465-7E0, HD605-7E0 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
Gasket sealant
• Features: Silicon-based quick-setting sealant.

LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 HD465-7E0, HD605-7E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
HD465-7E0, HD605-7E0 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 HD465-7E0, HD605-7E0
Special tool list 1

(Rev. 2009.01)
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity : t . . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . . Special tools that will be useful if available and are substitutable with tools avail-
able on the market
a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respec-
tively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modifi-
cation.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools")
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
795-799-5410 Adapter t 1 Removal, installation of
1
795-799-5420 Remover t 1 injector assembly
Removal and installation of
2 795T-675-1110 Socket q 1 N Q
high-pressure pipings
Removal of engine front
3 795-931-1100 Seal puller assembly t 1
and rear seals
795T-621-1180 Push tool (For oil seal) t 1 Q
795T-621-1171 Push tool (For dust seal) t 1 Q Press fitting of engine front
4
795-902-1460 Bolt t 3 seal
Engine assembly A 01582-02218 Nut t 3

795T-621-1161 Push tool t 1 Q
795T-621-1190 Push tool t 1 Q Press fitting of engine rear
5
01050-32235 Bolt t 5 seal
01050-32245 Bolt t 5
792-420-1110 Centering tool t 1
792-420-1120 • Flange 2 Centring engine assembly
6 and torque converter,
790-413-1120 • Color 1 transmission assembly
01010-51230 • Bolt 8
7 790-331-1120 Wrench (angle) q 1 Angle tightening of bolt
790-501-5000 Unit repair stand t 1
Disassembly, assembly of
1 790-901-2110 Bracket t 1
trque converter assembly
790-901-3011 Plate t 1
Torque convertor
assembly Removal, installation of
2 790-101-1871 Nut wrench t 1
PTO nut
C Removal, installation of
3 792-103-5110 Wrench t 1
pump nut
792-420-1120 • Flange 2 Centring engine assembly
Torque convertor
4 and torque converter,
transmission assembly 790-413-1120 • Color 1 transmission assembly
01010-51230 • Bolt 8
Checking actuation of
Transmission assembly D 1 799-301-1600 Oil leak tester t 1
piston
HD465-7E0, HD605-7E0 7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
Disassembly, assembly of
1 790-901-5110 Bracket t 1
differential assembly
790-901-3420 Plate t 1
Diffelential assembly H 2 790-425-1660 Wrench t 1 Adjust side bearing preload

Removal, installation of
3 790-102-1130 Power wrench t 1
bearing cap bolt
4 797-101-1171 Power wrench t 1
pinion bearing lock nut
792T-422-1610 Spacer t 4 N Q
1 01010-61620 Bolt t 4
01643-31645 Washer t 4
2 795-102-2102 Spring washer t 1
spring
Final drive and rear
brake, parking brake J 792-520-2110 Installer t 1 Removal, installation of
assembly 3 floatin seal
792-520-1600 Push tool t 1 (for small diameter)
791-585-1510 Installer t 1 Removal, installation of

4 floatin seal
792-530-1700 Push tool t 1 (for large diameter)
792-103-4102 Push tool t 1

792-625-1300 Push tool t 1 Press fitting of bushing
1 (for front)
790-101-5421 Grip t 1 (for rear)
Suspension cylinder
Q 01010-81240 Bolt t 1
assembly
792-610-1000 Suspension tool t 1
Adjusting of suspension
2 792-610-1100 • Pump assembly 1
cylinder
792-610-1200 • Charging tool 1
790-502-1003 Repair stand t 1 Disassembly and assem-
1
790-101-1102 Hydraulic pump t 1 bly steering cylinder
2 790-102-3802 Wrench t 1 Removal of cylinder head
3 790-302-1270 Socket t 1 Removal of piston nut
790-201-1702 Push tool KIT t 1
790-101-1771 • Push tool KIT 1
4 Press fitting of bushing
790-101-5021 • Grip 1
Steering cylinder
U 01010-50816 • Bolt 1
assembly
790-101-1580 • Push tool KIT 1
5 Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 790-720-1000 Expander t 1
7 796-720-1650 Ring t 1 Removal of steerig cylinder
8 07281-01029 Clamp t 1
8 HD465-7E0, HD605-7E0
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-502-1003 Repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hoist cylinder
Removal, installation of cyl-
2 790-102-3802 Wrench t 1
inder dead
3 790-720-1000 Expander t 1
4 796-720-1680 Ring (for cylinder ) t 1 Removal of piston ring
5 07281-01580 Clamp (for cylinder ) t 1
792-201-7310 Push tool t 1
Press fitting of bushing
790-101-5421 Grip t 1
(for cylinder )
01010-81240 Bolt t 1
Hoist cylinder assembly U 6 790-201-1702 Push tool KIT t 1
790-201-1851 • Push tool 1 Press fitting of bushing
790-101-5021 • Grip 1 (for cylinder )
01010-50816 • Bolt 1
792-201-7410 Plate t 1
Press fitting of dust seal
790-101-5021 Grip t 1
(for cylinder )
01010-80816 Bolt t 1
7 790-201-1500 Push tool KIT t 1
790-201-1660 • Push tool 1 Press fitting of dust seal
790-201-5021 • Grip 1 (for cylinder )
01010-50816 • Bolt 1
Dump body
V 1 790-441-1320 Hook t 1 Lifting of dump body
assembly
HD465-7E0, HD605-7E0 9
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
A2 socket
A4 push tool (For oil seal)
10 HD465-7E0, HD605-7E0

A4 push tool (For dust seal)
A5 push tool (For both standard and sleeved seal)
HD465-7E0, HD605-7E0 11

A5 push tool (For sleeved seal)
J1 Spacer
12 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 13

© 2009 KOMATSU
All Rights Reserved
14 HD465-7E0, HD605-7E0
SEN02484-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 5
Removal and installation of cylinder head assembly ...................................................................................... 9
Removal and installation of engine front seal ............................................................................................... 21
Removal and installation of engine rear seal ................................................................................................ 24
Removal and installation of engine assembly ............................................................................................... 28
Removal and installation of radiator assembly ............................................................................................. 35
Removal and installation of output shaft assembly ....................................................................................... 39
Disassembly and assembly of output shaft assembly .................................................................................. 40
Removal and installation of brake and power train oil cooler assembly ....................................................... 43
HD465-7E0, HD605-7E0 1
Removal and installation of fuel 8. Remove high-pressure pipe (13).

supply pump assembly 1
Removal
k Stop the machine on a level ground and
lock the tires with chocks.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
a The work of aliging 1TOP and 6TOP is not

necessary.
a The special tool for pulling the gear out is not
necessary.
1. Close the fuel supply valve. 9. Disconnect clamp (14) and connector G (15).
2. Remove clamp (1) and move the hose.
3. Remove wiring harness mounting bolts (2) and

(3).
4. Remove wiring harness mounting bolt (4).
5. Disconnect connectors PCV2 (5) and PCV1

(6).
10. Disconnect tubes (16) – (19). [*1]
11. Remove brackets (20) and (21).
12. Remove oil tube (22).
6. Remove bracket (7) and clamps (8) – (10).
7. Remove rubber caps (11) and (12) from high-

pressure pipe (13).
a The rubber caps are fixed with clamps.
Keep those clamps after removing the
rubber caps.
2 HD465-7E0, HD605-7E0
13. Remove the followings from fuel supply pump 2. Assemble the fuel supply pump assembly by
assembly (23). aligning (A) and (AA) at the position where a
1) Oil tube (24) spline tooth is missing.
2) Plate (25)
3) Overflow pipe adapter (26)
Installation
1. Install the followings to fuel supply pump
assembly (23).
1) Plate (25)
2) Oil tube (24)
3) Overflow pipe adapter (26)
3 Plate (25) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Oil tube (24) joint bolt:
Top: 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Bottom: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3. Install the followings from fuel supply pump
assembly (23).
3 Fuel supply pump mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
HD465-7E0, HD605-7E0 3
High-pressure piping 9. Install covers (11) and (12).

k When handing the high-pressure pipe
and clamp, pay attention the following.
q It is strictly prohibited to bend the
high-pressure piping to use it again or
using it in other locations.
q Install the specified clamp securely in
the specified position with the speci-
fied torque.
q Don't apply lubricant and the like to
the high-pressure piping sleeve nut
and the threaded portion of the mat-
ing side.
a Axial force in the tightening can be
excessive, potentially damaging q Carry out the succeeding installation in the
k Before installing the high-pressure pip-
reverse order of removal.
ing, check it for the following defects. [*1]
3
If there is any of these defects, it can Tube (18)
cause fuel leakage. Accordingly, Joint bolt (Overflow valve):
replace the high-pressure piping. 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
q Check the taper seal of the connect- Joint bolt (Supply pump side):
ing part (Part (a): Part of 2 mm from 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
the end) for visible lengthwise slit (b) Sleeve nut (Fuel block side):
and dent (c). 54 – 93 Nm {5.5 – 9.5 kgm}
3 Tube (19)
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for Joint bolt (Supply pump side):
stepped-type wear (fatigue) which 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
your nail can feel. Sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
3 Tube (16) joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Sleeve nut (Pre-filter side):
128 – 186 Nm {13 – 19 kgm}
a When tightening, fix the union with a spanner.
3 Tube (17) joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
4. Tighten high-pressure piping (13) temporarily. not, secure the clearance by adjusting the
wiring harness position.
5. Tighten clamps (8) to (10) temporarily.
q Bleeding air
6. Tighten high-pressure piping (13) permanently. Bleed air from the fuel system, referring to
3 High-pressure piping sleeve nut: "Bleeding air from fuel system" in Testing and
39.2 – 44.1 Nm {4.0 – 4.5 kgm} adjusting.
7. Tighten clamps (8) to (10) permanently.

3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
8. Tighten bracket (7) permanently.
4 HD465-7E0, HD605-7E0
Removal and installation of fuel 8. Remove cover (8).

injector assembly 1 9. Remove cover (9) and clamp (10) and (11) and
bracket (12).
Special tools
New/Remodel
10. Remove clamp (13).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
795-799-5410 Adapter t 1
1
A 795-799-5420 Remover t 1
2 795T-675-1110 Socket q 1 N Q
Removal
k Disconnect the cable from the negative (–)
terminal of the battery. 11. Disconnect sleeves (18) and (19).
a The procedure for removing the No.1 fuel
injector assembly is explained in this section. 12. Remove high-pressure pipings (14).
a Which part will be an obstacle to work
despends on which part will be removed. Take
care.
2. Remove washer tank (1).
3. Remove cover (2).
4. Disconnect tube (3).
6. Remove plate (5) and tube (6). a When tool A2 is not available, disconnect
sleeve (19) through the top.
7. Remove cylinder head cover (7). q Tool A2
a Before removing the cylinder head cover,
remove any part which may be an obsta-
cle to work.
HD465-7E0, HD605-7E0 5
13. Disconnect terminal mounting nuts (15). Installation

a Loosen the nuts alternately. Fuel injector
a Check that the inside of the injector sleeve is
14. Remove wiring harness assembly mounting free from dirt.
2 O-ring: Engine oil (EO30)
bolts (16) and spacer (17).
15. Remove fuel injector holder (21). 1. Assemble gasket (24) and O-rings (25) and
(26) to fuel injector (22).
a Use care not to install O-ring (25) in
groove (A) at the center.
2. Insert fuel injector (22) to adapter (27) and

injector holder (21).
3. Attach spherical washer (30) to bolt (29) and

then tighten injector holder (31) temporarily
2 Spherical washer: Engine oil (EO30)
a Tightening of injector holder (21) perma-
nently after tightening the high-pressure
piping temporarily.
16. Using tool A1, remove fuel injector assembly
(22).
a Remove the assembly by hitching tip of
tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pli-
ers.
Injector wiring harness

4. Install spacer (17)
a When installing the spacer, direct its slit
(B) toward the upside.
6 HD465-7E0, HD605-7E0
5. Install terminal mounting nut (15) and wiring 6. Install O-ring (32) to sleeve (31) of high-pres-
harness fixing bolt (16). sure piping (14).
a Tighten the terminal mounting nuts alter- 2 O-ring: Engine oil (EO30)
nately.
3 Terminal mounting nut: 7. Tighten sleeve nut (19) temporarily aligning it
2 ± 0.2 Nm {0.2 ± 0.02 kgm} connector (28) of the injector.
a When it is difficult to hitch sleeve nut (19)
to the threaded portion, turn the spanner
while pushing sleeve nut (19) end toward
the injector using a short bar and the like.
8. Tighten the common rail side sleeve nut (18)

temporarily, too.
9. Tighten injector holder (21) permanently.

3 Injector holder mounting bolt:
58.9 – 73.5 Nm {6.0 – 7.5 kgm}
10. Tighten high-pressure piping sleeve nut (18)

and (19) permanently using the spanner type
High-pressure piping
k When handing the high-pressure pipe and
torque wrench.
3 Sleeve nut:
clamp.pay attention the following. 39.2 – 44.1 Nm {4 – 4.5 kgm}
q It is strictly prohibited to bend the high- a After finishing the work, check that O-ring
pressure piping to use it again or using it (32) is not projected from the end of the
in other locations. sleeve nut (9).
q Install the specified clamp securely in the
specified position with the specified
torque.
q Don't apply lubricant and the like to the
high-pressure piping sleeve nut and the
threaded portion of the mating side.
excessive, potentially damaging the
high-pressure piping.
k Before installing the high-pressure piping,
check it for the following defects. If there is
any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pressure
piping,
q Check the taper seal of the connecting
part (Part (a):Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
HD465-7E0, HD605-7E0 7
11. Install cylinder head cover (7) q Carry out the succeeding installation in the
a A different tightening torque is employed reverse order of removal.
for No.2 cylinder mounting bolt alone.
3 Cylinder head cover mounting bolt: k Make sure that a clearance of 10 mm mini-
No.1,3,4,5 and 6 cylinders: mum is provided between the high-pres-
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} sure piping and adjacent wiring harness. If
No.2 cylinder: not, secure the clearance by adjusting the
58.8 – 73.5 Nm {6 – 7.5 kgm} wiring harness position.
q Bleeding air
Bleeding air from the fuel system, referring to
"Bleeding air from fuel system" in Testing and
adjusting.
High-pressure piping clamp

12. Install the clamp on the high-pressure pipe in
1) Manually tighten high-pressure piping
clamps (13) temporarily in the position
indicated in the figure.
2) Manually tighten common rail side clamp
bracket (12) and clamp (10) temporarily
and then tighten clamp (10).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket
(12) to the specified torque.
4) Tighten high-pressure piping clamp (13).
3 High-pressure piping side clamp
bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5) Install cover (9) on the common rail side
sleeve nut.
a When installing it, direct the slit down-
ward.
8 HD465-7E0, HD605-7E0
Removal and installation of 7. Remove covers (7) and (8) and guard (9).
cylinder head assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
795-799-5410 Adapter t 1
1
795-799-5420 Remover t 1
A
2 795T-675-1110 Socket q 1 N Q
7 790-331-1120 Wrench (angle) q 1
8. Disconnect breather hose (10), cable (11) and
wiring harnesses (12), (13), (14), (15).
Removal
k
Stop the machine on a level ground and
k Raise the body and lock it with the lock pin.
terminal of the battery.
2. Remove washer tank (1).
4. Disconnect tube (3).
5. Remove cover (4). 10. Lift off battery box assembly (17).
4 Battery box assembly: 270 kg
6. Remove plate (5) and tube (6).
HD465-7E0, HD605-7E0 9
11. Disconnect hose (18), cable (19) and clamps 15. Remove fuel prefilter assembly (26).
(20). [*1]
12. Remove bands (21) and air cleaner assem-

blies (22).
16. Disconnect wiring harness (27).
13. Lift off air cleaner mounting bracket (23).

4 Air cleaner mounting bracket: 40 kg
17. Remove turbocharger coolant tubes (28) and

(29). [*3]
14. Disconnect 2 tubes (24) and the remove corro-

sion resistor (25). [*2]
10 HD465-7E0, HD605-7E0
18. Remove turbocharger lubrication tubes (30) 21. Lift and remove turbocharger and exhaust
and (31). mainfold assembly (34). [*4]
4 Turbochatger and exhaust mainfold
assenbly: 120 kg
19. Remove EGR bypass tube (32).
23. Remove boots (36) and clamps (37), (38) and

bracket (39).
24. Remove clamps (40).
25. Remove fuel supply pump assembly (41).
20. Remove tube (33) between the exhaust main-

fold and EGR cooler.
HD465-7E0, HD605-7E0 11
26. Disconnect sleeve nuts (42) and (43). 29. Lift and remove air intake manifold assembly
(72).
4
27. Remove 6 high-pressure pipings (44).
Air intake manifold assembly: 110 kg
a When tool A2 is not available, disconnect

sleeve nut (43) through the top. 30. Pull out pin (A) and then push in bolt (B).
q Tool A2 31. Barring using bolt (B) and then align 1.6 TOP.
(Confirm the result after removing plug (BB).)
a For above operation, see “Testing and
adjusting valve clearance” in Testing and
adjusting.
28. Remove diffuser (76).

a Take care a convexed tube bites into the
inner face of the diffuser (indicated as A).
q (a): shows the notch of flywheel housing.
12 HD465-7E0, HD605-7E0
32. Remove cylinder head cover (81). 41. Using tool A1, remove fuel injector assembly
a Referencing play of the rocker arm, con- (92).
firm which is currently selected No.1 TOP a Remove the assembly by hitching tip of
or No.6 TOP. tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pliers.
33. Disconnect terminal mounting nuts (82).

34. Remove wiring harness assembly mounting
bolts (83) and spacer (84). 42. Lift and remove cylinder head assembly (93).
4
35. Loosen locknut (85) and then loosen adjust-
Cylinder head assembly: 50 kg
ment screw (86).
36. Remove rocker arm assembly (87). 43. Remove the cylinder head gasket.
37. Remove plush rod (88).

38. Remove crosshead assembly (89).
39. Remove rocker housing (90).
40. Remove fuel injector holder (91).
HD465-7E0, HD605-7E0 13
Installation
Cylinder head assembly
1. Install the cylinder head gasket.

2. Lift and install cylinder head assembly (93).
4 Cylinder head assembly: 50 kg
a Check the punch mark on the mounting
bolt head. If 5 marks are punched, replace
it with a new one without using it.
a Tighten the mounting bolts in the following
order.
2 Cylinder head assembly mounting bolt: a After tightening the main bolt, apply a
Molybdenum disulfide grease (LM-P) punch mark (a) on its head (this mark shall
3 Cylinder head mounting bolts (1 – 7): not be applied to a new bolt).
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time: 90 – 120° retightening
a For retightening, use tool A7 (see Special
tool list). When not using tool A7, apply a
marking to the cylinder head and bolt with
a felt pen and then retighten the bolt by
90° – 120° (target is 120°).
3 Cylinder head assembly mounting bolts
(8 and 9):
93.2 – 103 kgm {9.5 – 10.5 kgm}
14 HD465-7E0, HD605-7E0
Fuel injector
a Make sure that inside of the injector hole is
free from dusts.
2 O-ring: Engine oil (EO30)
3. Assemble gasket (94) and O-rings (95) and
(96) to fuel injector (92).
a Use care not to install O-ring (95) in
groove (A) at the center.
4. Insert fuel injector (92) to adapter (97) and
injector holder (91).
5. Attach spherical washer (100) to bolt (99) and
then tighten injector holder (91) temporarily.
2 Spherical washer: Engine oil (EO30)
a Tightening of injector holder (91) is done

permanently after installing the intake
manifold and tightening the high-pressure
piping temporarily.
6. Install push rod (88).

a Check that the push rod end is securely
placed in the cam follower socket.
7. Apply gasket sealant and then install rocker

housing (90).
2 Rocker housing: Gasket sealant (LG-7)
a Diameter of the gasket sealant line shall
be 2 to 3 mm and it should be applied
along the housing groove as shown below.
3 Rocker housing mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
8. Install crosshead (89).
HD465-7E0, HD605-7E0 15
9. Adjust the crosshead in the following procedure. a After tightening the locknut, check the
1) Loosen locknut (102) and then loosen valve clearance again.
adjustment screw (103) to a position
where it does not contact with valve stem
(104).
2) Maintain the contact with valve stem (105)
on the push rod side by pressing the con-
tact surface against the rocker arm using
a finger.
3) Tighten adjustment screw (103) to confirm
the position where adjustment screw (103)
is contacted against valve stem (104).
4) Drive in adjustment screw (103) further by
20 – 30° from the contacting position
against valve stem (104).
5) Tighten locknut (102) while suppressing
move of adjustment screw (103). Injector wiring harness
3 Locknut: 11. Install spacer (84).
53.0 – 64.7 Nm {5.4 – 6.6 kgm} a When installing the spacer, direct its slit
(B) toward the upside.
Rocker arm assembly

10. Install rocker arm assembly (87). 12. Install terminal mounting nut (82) and wiring
a Insert respective rocker arm at a position harness fixing bolt (83).
where the riveted side of the shaft faces a Tighten the terminal mounting nuts alter-
the front side of the engine. nately.
a When installing, direct the wider seat of 3 Terminal mounting nut:
the shaft to the rocker arm housing. 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Make sure that the ball of adjustment
screw (86) is securely fitted to the push
rod socket.
a When tightening the mounting bolt, make
sure adjustment screw (86) is not pushing
the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
a Adjust valve clearance, referring to “Test-
ing and adjusting valve clearance” in Test-
ing and adjusting.
3 Locknut (85):
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
16 HD465-7E0, HD605-7E0
Air intake manifold assembly k Before installing the high-pressure pip-

13. Place diffuser (76) on air lifted intake manifold ing, check it for the following defects.
assembly (72) being lifted. If there is any of these defects, it can
4
cause fuel leakage. Accordingly,
Air intake manifold and diffuser assembly: replace the high-pressure piping.
135kg q Check the taper seal of the connect-
a Pay attention to biting of the tube into (A) ing part (Part (a): Part of 2 mm from
portion. the end) for visible lengthwise slit (b)
and dent (c).
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
14. Install air intake manifold assembly (72).

a Tighten the mounting bolts in the order
indicated in the figure (clockwise starting
at the center).
High-pressure piping
k When handing the high-pressure pipe
and clamp, pay attention the following.
q It is strictly prohibited to bend the
high-pressure piping to use it again or
using it in other locations.
q Install the specified clamp securely in
the specified position with the speci-
fied torque.
q Don't apply lubricant and the like to
the high-pressure piping sleeve nut
and the threaded portion of the mat-
ing side.
excessive, potentially damaging
HD465-7E0, HD605-7E0 17
15. Install O-ring (106) to high-pressure piping 20. Install cylinder head cover (81).
sleeve (101). a A different tightening torque is employed
2 O-ring: Engine oil (EO30) for No. 2 cylinder mounting bolt alone.
16. Tighten sleeve nut (43) temporarily aligning it 3 Cylinder head cover mounting bolt:
connector (98) of the injector. No.1, 3, 4, 5 and 6 cylinders:
a When it is difficult to hitch sleeve nut to the 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
threaded portion, turn the spanner while No. 2 cylinder:
pushing sleeve nut (43) end toward the 58.8 – 73.5Nm {6 – 7.5 kgm}
injector by use of a short bar and the like.
17. Tighten the common rail side sleeve nut (42)
temporarily, too.
18. Tighten injector holder (91) permanently.
3 Injector holder mounting bolt:
58.9 – 73.5 Nm {6.0 – 7.5 kgm}
19. Tighten high-pressure piping sleeve nuts (42)
and (43) permanently using the spanner type
torque wrench.
3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm}
a After finishing the work, check that O-
ring (106) is not projected from the
end of the sleeve nut (43).
18 HD465-7E0, HD605-7E0
High-pressure piping clamp Fuel supply pump

21. Install the clamp on the high-pressure pipe in 22. Install the fuel supply pump assembly by align-
the following procedure. ing (A) and (AA) at the position where a spline
1) Manually tighten 17 high-pressure piping tooth is missing.
clamps (107) temporarily in the position 3 Fuel supply pump mounting bolt:
indicated in the figure. 59 – 74 Nm {6 – 7.5 kgm}
2) Manually tighten common rail slide clamp
bracket (39) temporarily and then tighten
clamp (38) and (37).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket
(39) to the specified torque.
4) Tighten high-pressure piping clamp (107).
3 High-pressure piping side clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5) Install boot (36) on the common rail side
sleeve nut.
a When installing it, direct the slit down-
ward.
HD465-7E0, HD605-7E0 19
High-pressure piping [*4]

k Handle the high-pressure piping and Exhaust manifold assembly
clamp in the same way as the piping q When the exhaust manifold assembly was dis-
between the fuel injector and common assembled, apply connection (A) (2 locations)
rail (noted in the foregoing) is handled. with the adhesive (heat resistant sealing
23. Tighten high-pressure piping (110) temporarily. agent) before assembling it.
24. Tighten clamps (111), (112) and (113) temporar- 2 Exhaust manifold connection:
ily. Liquid adhesive (Holtz MH 705)
25. Tighten bracket (114) temporarily.
26. Tighten high-pressure piping (110) perma-
nently.
3 High-pressure piping sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
27. Tighten clamps (111), (112) and (113) perma-
nently.
3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
28. Tighten bracket (114) permanently.
29. Install boot (115).
a Tighten the mounting bolts in the following

order.
2 Exhaust manifold mounting bolt:
Seizure prevention compound (LC-G)
(NEVER-SEEZ [Bostik, Inc] or equiv-
alent)
3 Exhaust manifold mounting bolt:
1st time: 39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2nd time:
98.1 – 122.6 Nm {10 – 12.5 kgm}
q Carry out the succeeding installation in the

[*1]
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Tube (24) joint bolt (Corrosion resistor side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*3]
3 Coolant tube joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
20 HD465-7E0, HD605-7E0
Removal and installation of 2. Remove the fan belt (2). For details, see
engine front seal 1 "Replacement and adjustment of fan belt".
Special tools 3. Sling damper and pulley assembly (3), remove

the mounting bolts, and lift off the damper and
New/Remodel
pulley assembly.
4
Necessity
Sym-
Part No. Part name Damper and pulley assembly: 50 kg
Sketch
bol
Q'ty
3 795-931-1100 Seal puller assembly t 1
Push tool
795T-621-1180 t 1 Q
(For oil seal)
A Push tool
4 795T-621-1171 t 1 Q
(For dust seal)
795-902-1460 Bolt t 3
01582-02218 Nut t 3
Removal
k Stop the machine on a level ground and 4. Remove dust seal (4).
lock the tire with chocks.
k Raise the body and lock it with the lock pin. 5. Remove front seal (5) in the following proce-
k Disconnect the cable from the negative (–) dure.
1. Remove fan (1).
1) Replace the tip of tool A3 with the hook

type one.
2) Hitch the hook to the hoop of front seal
(5).
3) Remove the seal using impacts of the
slide hammer (SH).
q Tool A3
HD465-7E0, HD605-7E0 21
a CS: Crankshaft Installation
1. Clean, degrease and then dry the contact sur-

face between the front cover and front seal.
2. Using a clean cloth, remove foreign matter
deposited the crankshaft flange.
a Clean foreign matter deposited on the seal
lip surface (surface around the crank
shaft) and then degrease and dry the sur-
face.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. Install front oil seal (5) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
1) Install the oil seal directing its side
stamped with IN toward the inside of the
engine.
a Pay attention to the assembling direc-
tion.
a The OUT stamped side is directed
toward the outside of the engine.
22 HD465-7E0, HD605-7E0
2) Using tool A4 (for oil seal), press fit oil

seal (5) to the front case in such that
dimension (a) in the figure is met.
a Oil seal press fitting dimension (a):
18.5 mm (when measured from the front
cover end face)
3) Using tool A4 (for dust seal), press fit dust

seal (4) to the front case in such that
dimension (b) in the figure is met.
a Dust seal press fitting dimension (b):
2 mm (Projection out of the front
cover end face)

[*1]
3 Pulley and damper mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6 Nm {23 – 27 kgm}
3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
HD465-7E0, HD605-7E0 23
Removal and installation of 3. Remove rear seal (2).

engine rear seal 1 a Take care in the removal not to damage
the seal installation position on the fly-
Special tools wheel housing and the seal contact sur-
face on the crankshaft.
New/Remodel
a Before removing, slightly drive the seal in
Necessity
Sym- once to free it from fixation.
Part No. Part name
Sketch
bol a When rear seal (2) is fixed too hard to the
Q'ty
flywheel housing (FWH), remove the fol-
Seal puller lowing procedure.
3 795-931-1100 t 1 a The left one in the following figure is the
assembly
standard seal and the right one is the
795T-621-1161 Push tool (*1) t 1 Q
A sleeved seal.
795T-621-1190 Push tool (*2) t 1 Q 1) Replace the tip of tool A3 with the drill
5
01050-32235 Bolt t 5 type one.
01050-32245 Bolt t 5 2) Drill several holes about 3 mm in diameter
into rear seal (2).
*1: For both standard and sleeved seal 3) Set tool A3 to the drilled hole. (Tip: Drill
*2: For sleeved seal type)
Removal 4) Remove rear seal with impact of slide
k Stop the machine on a level ground and hammer (SH).
lock the tire with chocks. a When the sleeve is attached, cut sleeve
k Raise the body and lock it with the lock pin. (5) using a gad and hammer to remove it.
k Disconnect the cable from the negative (–) a Take care not to damage crankshaft (4).
terminal of the battery. a Remove all the chips.
1. Remove the output shaft assembly, referring to

“Removal and installation of damper assembly.”
2. Lift and remove flywheel (1). [*1]

4 Flywheel assembly: 85 kg
q Tool A3
24 HD465-7E0, HD605-7E0
Installation q Procedure for installing standard seal

q Selection of rear seal a Don't apply gear or oil to the seal lip surface.
a Check the wear of the crankshaft and replace it 1) Contact larger inner diameter side (b) of
with the “Standard seal” or “Sleeved seal”. plastic inside cylinder (3) of rear seal (2)
a When wear on the crankshaft is not serious against the end face of crankshaft (4).
and only makes it look lustrous (depth of wear a Take care not to mistake the direction
is 10 µm or less when checked with finger of the plastic inside cylinder.
cushion) and no scratch is recognized, assem-
ble the standard seal (A). When the above is
not applicable, assemble sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling
the assembly guide.
a (5): Shows the sleeve.
a Don't remove assembly guide (3) from rear
seal (2) until the assembly is complete.
a Handle rear seal (2) and sleeve (5) as an inte-
gral part. Don't try to separate them.
2) Applying equal force to both hands, push

in the hoop of rear seal (2).
3) After pushing in rear seal (2), remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
a Clean, degrease and then dry the contact sur-

face between the rear seal and flywheel hous-
ing.
a Clean foreign matter deposited on the seal lip
surface (surface around the crank shaft) and
then degrease and dry the surface.
a Check the crankshaft end face corner and lip
siding surface for scratches due to the hous-
ing, burrs or rusts.
HD465-7E0, HD605-7E0 25
4) Tighten the bolts (35 mm) evenly to press a Tighten tool A5 (for both standard and
fit rear seal (2) until the end of tool A5 (for sleeved seal) first until it reaches the
both standard and sleeved seal) reaches bolt (45 mm) and then tighten the bolt
the end of crankshaft (4). (35 mm).
a Oil seal press fitting dimension (when a Rear seal driving depth (a): 20 mm
measured from the shaft end face) from end of crankshaft.
(a): 20 mm a After press fitting the seal, remove the
a After press fitting the rear seal, red sealant layer from its periphery.
remove the red sealant layer from its
periphery.

q Procedure for installing sleeved seal reverse order of removal.
a When installing the rear seal, do not apply oil [*1]
or grease to the crankshaft (4) and sleeve Flywheel assembly
inside cylinder surface (C). a Check the punch mark on the mounting bolt
1) Set sleeve and rear seal assembly (6) to head. If 5 marks are punched, replace it with a
tool A5 (for sleeved seal) new one without using it.
2 Sleeve inside cylinder surface (C): a In order to prevent the flywheel from rotating,
Gasket sealant (LG-7) fix the space between the flywheel and fly-
2) Set sleeve (5) of the rear seal to the end of wheel housing using the bolt hole.
crankshaft (4) and tighten the 5 bolts (45 a Tighten the mounting bolts in the following
mm) evenly to press fit sleeve and rear order.
seal assembly (6) until the end of tool A5 2 Flywheel assembly mounting bolt:
(for sleeved seal) reaches the end of Engine oil (EO30-DH)
3 Flywheel assembly mounting bolt:
crankshaft (4).
1st time : 196.1 ± 19.6 Nm {20 ± 2 kgm}
2nd time : 460.9 ± 19.6 Nm {47 ± 2 kgm}
3rd time : 90 – 120° retightening
a After tightening the bolt, make a punch mark
(a) on its head. (When a new bolt is used, do
not make a punch mark on its head.)
3) Remove tool A5 (for sleeved seal) and

install tool A5 (for both standard and
sleeved seal).
4) Tighten the 5 bolts evenly to press fit
sleeve and rear seal assembly (6) until the
end of tool A5 (for both standard and
sleeved seal) reaches the end of crank-
shaft (4).
26 HD465-7E0, HD605-7E0
q Measure radial runout or facial runout of the

flywheel using dial gauge [1].
a Standard radial and facial runout:
Measuring
Tolerance (mm)
items
Radial
0.13
runout
Facial 0.0005 × Diameter of
runout measuring point
a When the measured value is out of the

standard, determine the cause by disas-
sembling the flywheel again.
HD465-7E0, HD605-7E0 27
Removal and installation of 2. Remove the radiator assembly. For details,

see "Removal and installation of radiator
engine assembly 1 assembly".
Special tools
3. Remove the radiator cross bar (1).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-420-1120 • Flange 2
A6
790-413-1120 • Color 1
01010-51230 • Bolt 8
Removal
a Check the thickness and quantity of the shims
lower the work equipment and touch per-
inserted in part (a) on the left side. [*2]
fectly to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal of the
battery beforehand.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put 4. Disconnect hose (2) and connector FL04 (3)
on protective goggles, gloves and and remove washer tank (4).
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 1,100 g
28 HD465-7E0, HD605-7E0
5. Remove covers (5) and (6) and guard (7). 9. Disconnect elbow (16), cable (17) and clamp
(18). [*3]
10. Remove band (19) and air cleaner assembly

(20).
6. Disconnect breather hose (8), cable (9) and

wiring harnesses (10) – (13).

11. Lift off air cleaner mounting bracket (21).
4 Air cleaner mounting bracket: 40 kg
8. Lift off battery box assembly (15).

4 Battery box assembly: 270 kg
12. Disconnect hoses (22) – (26).
HD465-7E0, HD605-7E0 29
13. Disconnect cable (27) and clamp (28). 17. Disconnect ground cable (36) and air intake
connector (37).
q Left side of engine

14. Disconnect ground cable (29), alternator E wir- 18. Disconnect clamps (38) and (39), remove
ing harness E06 (30), alternator B wiring har- cover (40), and disconnect connector J2P (41).
ness E09 (31) and alternator R wiring harness
E01 (32).
19. Disconnect ground cable (42).
15. Disconnect compressor connector E07 (33).
16. Disconnect air compressor hoses (34) and

(35).
30 HD465-7E0, HD605-7E0
20. Disconnect engine oil level gauge connector q Right side of engine
E04 (43). 23. Disconnect clamp (50), wiring harness E5 (51),
starting motor cables (52) and (53), connector
E02B (54) and connector E02A (55).
21. Disconnect engine oil pressure sensor POIL

(44).
24. Disconnect clamps (56) and remove mounting
bolt (57).
25. Disconnect water hoses (58) and (59).
26. Disconnect clamp (60) and hose (61).
27. Remove tubes (62), (63) and (64).
22. Disconnect fuel hose (45), engine oil hoses

(46) and (47) and fuel return hoses (48) and
(49).
q Rear side of machine

28. Disconnect clamps (65) and (66) and remove
cover (67).
29. Disconnect ground cable (68).
HD465-7E0, HD605-7E0 31
30. Disconnect clamp (69). 33. Remove guard (76) and disconnect drive shaft
assembly (77). [*4]
31. Remove exhaust tube cover (70) and heat

shield covers (71) – (73). 34. Sling the engine assembly.
35. Remove engine mounting bolts (78), (79) and

(80). [*5] [*6]
32. Remove clamp (74) and exhaust tube (75).
32 HD465-7E0, HD605-7E0
36. Pull engine assembly (81) forward to remove.

a Check that all the wirings and pipings are
disconnected and take care that the
engine will not interfere with the machine.
4 Engine assembly: 3,088 kg
HD465-7E0, HD605-7E0 33
Installation Reference: The allowable vertical and lateral

q Carry out installation in the reverse order to deviation between both flanges is
removal. 3 mm maximum.
[*1]
Charge the air conditioner circuit with refrigerant
(R134a air conditioner gas).
a Take care that dirt, dust, water, etc. will not
enter the air conditioner circuit.
a Before proceeding to the installation, check
that the O-ring is provided at the air conditioner
hose connection.
a Check the O-ring for scratches or degradation.
2 O-ring: ND-OIL8
q Quantity of refrigerant: 1,110 g
[*2]
3
q Standard total shim thickness: 2.0 mm Engine mount mounting bolt (Both front and
q Thickness of each shim: 1.0 mm rear): 343 – 426.3 Nm {35.0 – 43.5 kgm}
a If the engine mount bracket was removed from
the chassis, tighten its mounting bolts to the
following torque.
3 Mounting bolt of front engine mount bracket:
343 – 426.3 Nm {35.0 – 43.5 kgm}
3 Mounting bolt of rear engine mount bracket:
450 – 608 Nm {50 – 62 kgm}
[*6]
a Install the engine assembly so that the clear-
ance between the engine damper and support
will be (a) (10.5 ± 2.5 mm).
[*3]
3 Clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
a When tightening the bolts, check that the
groove of the spider cap is fitted to the groove
of the mating yoke.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*5]
a Center the engine assembly and torque con- q Refilling with coolant
verter and transmission assembly according to Add coolant through the coolant filler to the
the following procedure. specified level. Run the engine to circulate the
1. Install flange (A6-1) and collar (A6-2) of tool A6 coolant through the system. Then, check the
between coupling (20) on the engine side and coolant level again.
5
coupling (21) on the torque converter side.
2. Center the engine assembly and torque con- Coolant: 157 l
verter and transmission assembly by moving
the engine assembly so that collar (A6-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
34 HD465-7E0, HD605-7E0
Removal and installation of 6. Remove rubber cap (5) and guard mounting
bolt.
radiator assembly 1
Removal
1. Remove the rubber cap and radiator cover (1).
2. Drain the coolant.

5 Coolant: 157 l
7. Remove cap (6) and radiator grille (7) mount-

ing bolt.
3. Disconnect gas spring (2).

a Sling the engine hood assembly first and
then remove the gas spring.
4. Disconnect stay (3). 8. Remove baffles (8) and (9) and pipe (10).
5. Lift off engine hood assembly (4).

4 Engine hood: 50 kg
HD465-7E0, HD605-7E0 35
9. Lift off guard (11). 19. Disconnect aftercooler tube mounting bracket
a Check the thickness and quantity of the (25) and remove aftercooler tube (26). [*4]
shims.
4 Guard: 110 kg
20. Disconnect aftercooler tube mounting brackets

(27) and (28) and remove aftercooler tube
10. Remove baffles (12) and (13). (29). [*5]
11. Remove condenser (14) and oil cooler (15) 21. Disconnect hose mounting clamps (30) and
and put them aside so that they will not be (31).
obstacles to work.
a Do not disconnect the hoses. 22. Disconnect reservoir tank (32) and put it aside
so that it will not be an obstacle to work.
12. Disconnect horn connector HN1 (HIGH) (16) a Do not disconnect the hoses.
and connector HN2 (LOW) (17).
13. Remove baffles (18) and (19).
23. Disconnect clamp (33).
24. Disconnect heater hose mounting clamp (34).

14. Disconnect radiator coolant level sensor con-
nector FL02 (20).
15. Remove radiator inlet hose (21). [*1]
16. Disconnect 3 air hoses (22). [*2]
17. Disconnect the reservoir tank hose and drain

hose (23). [*3]
18. Remove cushioned cover (24).
36 HD465-7E0, HD605-7E0
25. Disconnect coolant hose (35). [*6] 28. Lift off radiator assembly (38).
4 Radiator asembly: 405 kg
26. Remove radiator upper mounting nut (36).

a Before removing, check dimension (a) on
both sides. Installation
q Carry out installation in the reverse order to
27. Remove radiator lower mounting bolt (37). removal.
a Sling the radiator assembly and then
remove the mounting bolt. [*1]
a When using 2 clamps, set them 180° apart
from each other as shown in the figure.
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5
kgcm}
[*2] [*3]
a Install the hose clamp as showm in the figure.
3 Hose clamp: 3.3 ± 0.49 Nm {34 ± 5 kgm}
HD465-7E0, HD605-7E0 37
[*4] [*5]
a When using 2 clamps, set them 180° apart a Set the projection of the screw tip as follows
from each other as shown in the figure. when the screw is tightened to the specified
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 torque.
kgcm} Part (a) of tip: 5.1 mm
a Set the projection of the screw tip as follows [*6]

when the screw is tightened to the specified a When using 2 clamps, set them 180° apart
torque. from each other as shown in the figure.
Part (a) of tip: 5.1 mm 3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5
kgcm}
a Adjust bracket (27) so that clearance (b)

between tube (28) and radiator will be at least
13 mm. q Refilling with coolant
Add coolant through the coolant filler to the
specified level. Run the engine to increase the
coolant temperature. Then, check the coolant
level again.
5 Coolant: 157 l
38 HD465-7E0, HD605-7E0
Removal and installation of Installation

output shaft assembly 1 q Carry out installation in the reverse order to
removal.
Removal a For application of ENS grease to each part,
k Stop the truck on level ground and set the see Disassembly and assembly.
parking brake switch to the PARK position,
[*1]
2
then lock the wheels with blocks.
k
Mounting bolt: Adhesive (LT-2)
3
Raise the dump body and lock it with the
lock pin. Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Remove drive shaft assembly (1). [*1]
4 Drive shaft assembly: 30 kg
[*2]
3 Mounting bolt:
2. Remove coupling (2). 98 – 123 Nm {10 – 12.5 kgm}
[*3]
3
3. Remove cover (3). [*2]
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*4]
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4. Remove snap ring (4).
5. Remove the bearing and cover (5) together.

[*3]
a Use the guide bolt and forcing screws to
remove the bearing and cover.
4 Cover assembly: 35 kg
6. Lift off output shaft assembly (6). [*4]

4 Output shaft assembly: 90 kg
HD465-7E0, HD605-7E0 39
Disassembly and assembly of

output shaft assembly 1
Disassembly
1. Oil cage assembly
Remove oil seal (1) from cover (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Disassembly of damper assembly (5)

1) Before disassembling, make marks of
flange (6), body assembly (7), and body
outer (9) for balancing them for reassem-
bly.
2) Remove body assembly (7) and rubber
pieces (8) from body outer (9).
a There are 2 rubber pieces (8), large
one and small one. Check their loca-
tions.
3) Remove bearing (10) from the flywheel.
40 HD465-7E0, HD605-7E0
Assembly 3. Install damper assembly (5) to the flywheel.

2 Spline of body assembly shaft:
ENS grease
4. Press fit bearing (3) to cover (4).

2 Bearing: ENS grease
5. Install cover assembly to the flywheel.

4 Cover assembly: 55 kg
2 Mating faces of cover assembly and fly-
wheel: Gasket sealant (LG-6)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6. Fit oil seal (1) to cover (2).

2 Insertion part of cover and outside of oil
seal: LOCTITE 648 (287-01-12830)
a Degrease and dry the above parts before
applying gasket sealant.
2 Mating faces of covers (2) and (4):
Gasket sealant (LG-6)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Using the push tool, press fit bearing (10) to

the flywheel.
2 Bore of bearing: ENS grease
2. Assembly of damper assembly

1) Apply gasket sealant to body outer (9) and
the mating face of flange (6), then install
them.
2 Mating face of flange:
2) Install body assembly (7).
3) Install body outer (9), body assembly (7),
and rubber pieces (8).
a When installing large and small rubber
pieces (8), check their locations.
a Before installing these parts, apply grease
to them.
2 Body outer, body assembly, and
rubber pieces: Grease (G2-LI)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4) Install flange (6).
2 Mating face of flange:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a When installing the body outer, body inner,
and flange, match them to their marks.
HD465-7E0, HD605-7E0 41
7. Install the cage assembly to the cover assem-

bly.
q Procedure for filling ENS grease

1) Part No. of ENS grease: 427-12-11871
2) Parts to be filled with ENS grease, quan-
tity of ENS grease to be supplied (Total:
Approx. 500 g), and parts to be coated
with ENS grease are shown below.
42 HD465-7E0, HD605-7E0
Removal and installation of brake 6. Remove tubes (5) and (6). [*2]
and power train oil cooler
7. Supporting the brake and power train oil cooler
assembly 1 assembly (7) with jacks, etc., remove them.
[*3]
4 Brake and power train oil cooler assem-
Removal
k Stop the machine on a level ground and bly: 145 kg
1. Remove the engine underguard (1).

a Remove only the 2 mounting bolts on the
front side.
2. Drain the engine oil and hydraulic oil.

6 Engine oil pan: 70 l
6 Hydraulic tank (Steering, hoist oil tank):

122 l
3. Drain the coolant
5 Coolant: 157 l
4. Disconnect hoses (2) and (3). [*1]

Installation
removal.
[*1]
a Install the hose so that it will not twist.
a When using 2 clamps, set them 180 degrees
apart from each other as shown in the figure.
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5
kgcm}
5. Disconnect hose (4) from the underside of the

cooling fan.
HD465-7E0, HD605-7E0 43
[*2]
a Install the hose so that it will not twist.
a When using 2 clamps, set them 180° apart
from each other as shown in the figure.
3 Hose clamp: 13.7 ± 0.5 Nm {140 ± 5
kgcm}
[*3]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[Target: 279 Nm {28.5 kgm}]
q Refilling with oil

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Engine oil pan:
70 l (EO10-CD or EO30-DH)
5 Hydraulic tank: 122 l (EO10-CD)
q Refilling with coolant

specified level. Run the engine to increase the
coolant temperature. Then, check the coolant
level again.
5 Coolant: 157 l
44 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 45

© 2009 KOMATSU
All Rights Reserved
46 HD465-7E0, HD605-7E0
SEN02485-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Power train, Part 1
Removal and installation of torque converter and transmission assembly ..................................................... 2
Separation and coupling of transmission assembly and torque converter assembly ..................................... 5
Disassembly and assembly of transmission assembly and torque converter assembly................................. 6
Disassembly and assembly of torque converter assembly ............................................................................. 8
Disassembly and assembly of transmission assembly ................................................................................. 18
Removal and installation of transmission control valve assembly (ECMV assembly) .................................. 49
Disassembly and assembly of transmission control valve assembly (ECMV assembly) .............................. 50
HD465-7E0, HD605-7E0 1
Removal and installation of 5. Remove drive shaft (5). [*1]

4 Drive shaft: 65 kg
torque converter and
transmission assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-420-1120 • Flange 2
C4
790-413-1120 • Color 1
01010-51230 • Bolt 8
6. Disconnect clamp (6) and hoses (7) – (9).
Removal
k Raise the dump body and lock it with the
safety pin.
1. Remove 2 mounting bolts (1) and disconnect

transmission underguard (2).
7. Disconnect hoses (10) – (13).
2. Drain the transmission oil and hydraulic oil.

6 Transmission case: 215 l
6 Hydraulic tank: 122 l
3. Disconnect wiring connectors (3) (TM2 and

TM3).
4. Disconnect breather hose (4).
2 HD465-7E0, HD605-7E0
8. Remove guard (14) and disconnect drive shaft 12. Remove mounting bolts (23) and (24) of the
(15). [*2] front and rear mounts, then remove torque
converter and transmission assembly (25).
[*3]
a When removing the torque converter and
transmission assembly, check that the all
wires and pipes are disconnected and
take care that the assembly will not inter-
fere with the chassis.
a Check the thickness and quantity of the
shims set in the rear mount.
q Standard thickness of shims: 2 mm
q Thickness of each shim: 0.5 mm (1
type)
4 Torque converter and transmission as-
sembly: 1,700 kg
9. Disconnect tubes (16) and (17), hose (18) and
tubes (19) and (20).
10. Remove coupling (21) and disconnect hose

(22).
11. Sling the torque converter and transmission

assembly temporarily.
HD465-7E0, HD605-7E0 3
Installation q Refilling with oil

q Carry out installation in the reverse order to Add oil through the oil filler to the specified
removal. level. Run the engine to circulate the oil
through the system. Then, check the oil level
[*1] [*2] again.
a When tightening the bolts, check that the 5 Transmission case: 215 l (EO30-CD)
5
groove of the spider cap is fitted to the groove Hydraulic tank: 122 l (EO10-CD)
of the mating yoke.
[*1]
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*3]
a Center the engine assembly and torque con-
verter and transmission assembly according to
1. Install flange (C4-1) and collar (C4-2) of tool
C4 between coupling (20) on the engine side
and coupling (21) on the torque converter side.
2. Center the engine assembly and torque con-
verter and transmission assembly by moving
the engine assembly so that collar (C4-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
Reference: The allowable vertical and lateral
deviation between both flanges is
3 mm maximum.
aIf the transmission mount bracket was

removed from the chassis, tighten its
mounting bolts to the following torque.
3 Mounting bolt:
450 – 608 Nm {50 – 62 kgm}
4 HD465-7E0, HD605-7E0
Separation and coupling of 5. Lift off torque converter assembly (10). [*1]
4 Torque converter assembly: 412 kg
transmission assembly and
torque converter assembly 1 6. Remove seal rings (11) and (12). [*2]
Separation
1.Remove pump assemblies (1), (2), and (3) and
their pipes.
4 Retarder cooling pump assembly (1): 40 kg
4 Steering hoist and hoist control pump as-
sembly (2): 38 kg
4 Torque converter, transmission lubrication,
retarder cooling, and brake control pump
assembly (3): 26 kg
2. Remove guard (4) and trunnion (5).
3. Remove cover (6), (7) and disconnect torque

converter outlet oil temperature sensor con-
nector (8) and torque converter intermediate oil
pressure sensor connector (9).
Coupling
q Carry out coupling in the reverse order to sep-
aration.
[*1]
3 Torque converter assembly mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
[*2]
2 Outside of seal ring: Grease (G2-LI)
4. Sling the torque converter and transmission

assembly, then place it with the torque con-
verter side up.
HD465-7E0, HD605-7E0 5

transmission assembly and
torque converter assembly 1
Disassembly
1. Remove pressure switch (2) and solenoid
valve assembly (3) from body (1).
2. Remove ball (4), valve (5) and plug (6) from

valve body (10).
3. Remove plug (7), spool (8) and spring (9) from

valve body (10).
4. Remove valve body (10) from body (1).
5. Remove piston (11), valve (12), spring (13)

valve (14) and main relief valve (15) from body
(1).
6. Remove cover (16) from body (1) and then

remove shim (17) and spring (18).
a Check the quantity and thickness of the
shims.
7. Remove plug (19), spool (20) and cover (21)

from body (1).
8. Remove cover (22), shim (23) and spring (24)

from body (1).
a Check the quantity and thickness of the
shims.
9. Remove plate (25) from body (1) and then

remove valve (26), spring (27), valve (28) and
torque converter relief valve (29).
6 HD465-7E0, HD605-7E0
Assembly
a Check all the parts for dirt and damage and
coat their sliding surfaces with engine oil
before installing.
1. Fit the O-ring and install cover (25) to body (1).
2. Install spring (24), valves (28) and (26) and

spring (27) to torque converter relief valve (29),
and install them to body (1).
3. Set shim (23) to cover (22), fit the O-ring, and

install them to body (1).
4. Fit the O-ring and install cover (21) to body (1).
5. Fit the O-ring and install spool (20) to body (1).
6. Install spring (18), valves (14) and (12) and

spring (13) to main relief valve (15), and install
them to body (1).
7. Install piston (11) and plug (19) to valve body

(10), fit the O-ring, and install them to body (1).
8. Install spring (9) to spool (8), fit the O-ring, and

install plug (7).
9. Fit the O-rings to solenoid valve assembly (3)

and plug (6) and install ball (4) to valve (5).
10. Install valves (6) and (5) to valve body (10) and
install solenoid valve assembly (3).
11. Fit the O-ring and install pressure switch (2).
HD465-7E0, HD605-7E0 7
Disassembly and assembly of 5. PTO case assembly

1) Remove holder (6) and coupling (7).
torque converter assembly 1 a Before removing the holder and cou-
pling, loosen 3 nuts (8) with tool C2
Special tools
(Use the coupling as a stopper).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-901-2110 Bracket t 1
C 790-901-3011 Plate t 1
2 790-101-1871 Nut wrench t 1
3 792-103-5110 Wrench t 1
Disassembly
1. Set the torque converter assembly to tool C1. 2) Using 2 forcing screws [1], lift off PTO
case assembly (9).
2. Remove control valve assembly (1). a Before removing the PTO case as-
sembly, make match marks on it.
3. Remove torque converter oil temperature sen-
sor (2) and torque converter intermediate oil
pressure sensor (3).
4. Remove tube (4) and elbows (5).
6. Disassembly of PTO case assembly

1) Using tool C2, remove nuts (8).
2) Remove snap ring (10) and plate (11).
8 HD465-7E0, HD605-7E0
3) Press the shaft to remove PTO gear and 8) Remove oil seal (21) and dust seal (22)
bearing assembly (12). from the cage.
a If the PTO gear and bearing assem-
bly comes off, bearing (13) comes off,
too.
4) Remove inner race spacer (14) and bear-
ing (15) from the PTO gear.
5) Remove outer races (16) and (17) and
outer race spacer (18) from the PTO case.
a Since parts (13) – (18) form an as-
sembly, do not replace any of them
with one of another assembly. (The
combination symbol is stamped on
each part.)
9) Remove bushing (23) and outer race (24)

from the PTO case.
6) Remove snap ring (19).

7) Using forcing screws [2], remove cage
(20).
7. Turbine and clutch assembly
1) Remove mounting bolts (25) on the pump
side.
2) Remove turbine and clutch assembly (26).
HD465-7E0, HD605-7E0 9
8. Disassembly of turbine and clutch assem- 5) Turn over the clutch housing and remove
bly snap ring (34) and plate (35).
1) Input shaft
1] Using forcing screws [3], remove
input shaft (27).
2] Remove bearing (28) from the input
shaft.
6) Using push tool [4], remove shaft (36)

from clutch housing assembly (31), then
remove piston (37).
2) Turn over the drive case and remove the

mounting bolts and turbine (29).
7) Remove seal rings (38) from piston (37).
3) Remove drive case (30) from clutch hous-

ing assembly (31).
4) Remove 2 discs (32) and plate (33).
10 HD465-7E0, HD605-7E0
8) Using push tool [5], remove bearing (39) 2) Remove bushings (45) and (46) and free
from the clutch housing. wheel (47) from outer race (44).
9) Remove pin (40) and seal ring (41). a Take care not to lose balls (48).
9. Stator assembly 11. Disassembly of pump, stator shaft, and rear

Pull up and remove stator assembly (42). housing assembly
1) Remove snap ring (49) and inner race
(50).
2) Using tool C3, remove nuts (51).
10. Disassembly of stator assembly

1) Remove stator (43).
3) Remove the pump, stator shaft, and rear

housing assembly from tool C1.
4) Remove the mounting bolts and push out

and remove stator shaft (52).
a At this time, inner race (53) comes off.
HD465-7E0, HD605-7E0 11
5) Remove seal ring (54), inner race (55), Assembly

and sleeve (56) from stator shaft (52). 1. Assembly of pump, stator shaft and rear
housing assembly
1) Install bearing (60) to guide (59) and
install them to pump (57).
a Bearing (60) is an assembly. Check
that the serial No. and match symbol
(A or B) on its end face are the same
as those on the mating inner race.
2) Install retainer (58) to pump (57).
2 Retainer mounting bolt:
Adhesive (LT-2)
58.8 – 73.5 Nm {6 – 7.5 kgm}
6) Remove retainer (58) and guide (59) from

pump (57).
7) Remove bearing (60) from guide (59).
3) Press fit inner race (55) to stator shaft

(52).
a Inner race (55) is an assembly.
Check that the serial No. and match
symbol (A or B) on its end face are
the same as those on the mating
bearing.
4) Fit sleeve (56) and seal ring (55).
a Fit sleeve (56) by expansion fit.
2 Outside of seal ring:
Grease (G2-LI)
12 HD465-7E0, HD605-7E0
5) Install stator shaft assembly (52) to rear 8) Using tool C3, tighten nuts (51).
housing (61). a Drop about 6 CC of engine oil (EO10-
2 Mounting bolt: Adhesive (LT-2) CD or EO30-CD) over the bearing
3 Mounting bolt: and rotate the bearing 10 turns.
98.1 – 122.6 Nm {10 – 12.5 kgm} 2 Threads of nut: Adhesive (LT-2)
3 Nut:
441.3 – 490.3 Nm {45 – 50 kgm}
9) Install inner race (50) and snap ring (49).
a Install the inner race with the wider
end face up.
6) Install the stator shaft and rear housing

assembly to tool C1.
7) Install pump assembly (62) and inner race
(53) to stator shaft (52).
a Inner race (53) is an assembly.
Check that the serial No. and match 2. Assembly of stator assembly
symbol (A or B) on its end face are 1) Install free wheel (47) to outer race (44).
the same as those on the mating a Install the free wheel with its arrow
bearing. mark end on the input side. Check
the revolving direction of the outer
race, seeing it from the input side.
Clockwise: Free rotation
Counterclockwise: Locked
2 Sliding surface:
Engine oil (EO10-CD or EO30-CD)
2) Install balls (48) to outer race (44), then
install bushings (46) and (45) by expan-
sion fit.
2 Sliding surface:
HD465-7E0, HD605-7E0 13
3) Install stator (43). 3) Using push tool [6], install bearing (39) to
2 Mounting bolt: Adhesive (LT-2) the clutch housing.
3 Mounting bolt: a Press fit the bearing until it is stopped
58.8 – 73.5 Nm {6 – 7.5 kgm} by the clutch housing.
a Drop about 6 cc of engine oil (EO10-
CD or EO30-CD) over the bearing
and rotate the bearing 10 turns.
3. Stator assembly
Install stator assembly (42).
4) Install seal ring (40) to piston (39).

a For the installing direction, see the
following figure.
Grease (G2-LI)
4. Assembly of turbine and clutch assembly

1) Install seal ring (41) to the clutch housing.
a For the installing direction, see the
following figure.
Grease (G2-LI)
2) Install pin (40) by expansion fit. 5) Install piston (37) to clutch housing as-
sembly (31).
6) Using push tool [7], press fit shaft (36) to
clutch housing assembly (31).
a Press fit the shaft until it is stopped by
the bearing.
14 HD465-7E0, HD605-7E0
7) Install plate (35) to the shaft, then install 11) Input shaft
snap ring (34). 1] Using push tool [8], install bearing
(28).
a Drop about 6 cc of engine oil
(EO10-CD or EO30-CD) over the
bearing and rotate the bearing 10
turns.
2] Install input shaft assembly (27) to
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
269.7 – 308.9 Nm {27.5 – 31.5 kgm}
8) Install 2 discs (32) and plate (33).

2 Sliding surface of disc:
9) Install drive case (30) to clutch housing
assembly (31).
a Watch through holes (A) (at 6 places
on the periphery) and check that plate
(33) is meshed with the gear of drive
case (30).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm} 5. Turbine and clutch assembly
1) Install turbine and clutch assembly (26).
2) Tighten mounting bolts (25) (30 pieces).
3 Mounting bolt:
49.0 – 58.8 Nm {5 – 6 kgm}
10) Install turbine (29).

3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
HD465-7E0, HD605-7E0 15
6. Assembly of PTO case assembly 3) Fit the O-ring to cage (20) and install them
1) Press fit outer race (24) and bushing (23) to the PTO case.
to the PTO case. 4) Install snap ring (19).
a After press fitting bushing (23), bend a Install the snap ring so that its closed
the PTO case end (by 4 points equal- gap will be on the left side (in the
ly spaced on the periphery) with a direction of 9 o'clock) when it is on the
punch, etc. until it is over the bushing. truck and seen from the engine side.
2) Using push tool [9], install dust seal (22) 5) Install outer race spacer (18) and outer
and oil seal (21) to cage (20). races (16) and (17) to the PTO case.
1] Thinly apply gasket sealant (LG-5) to 6) Install bearing (15) and inner race spacer
the seal fitting surface inside the (14) to the PTO gear.
cage.ii) 7) Install PTO gear and bearing assembly
2] Install the seals so that the distances (12) to the PTO case, then install bearing
from the cage top to their tops will be (13) to the shaft.
as follows. a Since parts (18) – (13) form an as-
q Distance (a): 23.6 ± 0.2 mm sembly, do not replace any of them
q Distance (b): 8.75 ± 0.25 mm with one of another assembly. (The
a After installing, wipe off the pro- combination symbol is stamped on
jected gasket sealant thoroughly. each part.)
3] Fill the space between the oil seal a Apply grease (G2-LI) to the inside
and dust seal and the space between spline of the PTO gear shaft.
the lips of the oil seal with silicone
grease (ThreeBond 1855)
a Supply grease of quantity equiv-
alent to 40 – 60% of the space
between the lips so that it will not
be projected.
16 HD465-7E0, HD605-7E0
8) Install plate (11) and snap ring (10). 3) Using tool C2, tighten the nuts (8) to the
9) Using tool C2, tighten nuts (8) temporarily. following torque which were tightened
a Install the nuts with the chamfered temporarily in steps 6-9).
side down. a Use the coupling as a stopper.
a Tighten the nuts fully after installing 3 Nut:
the PTO case assembly. After this, 392.4 – 441.5 Nm {40 – 45 kgm}
follow the procedure: 7-3 (making
coupling serve as a stopper).
2 Threads of nut: Adhesive (LT-2)
8. Install elbows (5) and tube (4).

a When installing elbows (5), check that
there are stamps of <2> on their outside.
7. PTO case assembly 3 Elbow: 84 – 132 Nm {8.5 – 13.5 kgm}
1) Sling PTO case assembly (9) and fit the
O-ring. Using guide bolt [10], install the 9. Install torque converter intermediate pressure
PTO case assembly. sensor (3).
a When installing the PTO case assem- 3 Sensor: 29.4 – 49.0 Nm {3.0 – 5.0 kgm}
bly, match the match marks.
3 Mounting bolt: 10. Install torque converter oil temperature sensor
98.1 – 122.6 Nm {10 – 12.5 kgm} (2).
2 Threads of sensor:
3 Sensor: 29.4 – 49.0 Nm {3.0 – 5.0 kgm}
11. Install control valve assembly (1).

3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 Kgm}
2) Install coupling (7) and holder (6).

3 Mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
HD465-7E0, HD605-7E0 17
Disassembly and assembly of 4) Remove cover (7) and lubricating oil tem-
perature sensor (8).
transmission assembly 1 5) Remove block (9).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
D1 799-301-1600 Oil leak tester t 1
Disassembly
1. Transmission mount, cover, wiring har-
ness, and sensors
1) Remove both transmission mounts (1).
2) Remove covers (2) and (3). 2. Control valve assembly
1) Remove cover (10) and tube (11).
3) Remove input shaft speed sensor (4),

intermediate shaft speed sensor (5), and 2) Separate the connector of each control
output shaft speed sensor (6). valve and remove wiring harness (12).
3) Install a sling bolt to position [A] and
remove control valve assembly (13) and
valve seat together.
a After removing the control valve,
cover the oil holes on the mating face
of the transmission case with tapes,
etc. to prevent foreign matter from
entering the transmission case.
4) Remove each control valve (14) and filter
assembly (15) from the valve seat.
18 HD465-7E0, HD605-7E0
3. Sleeve 3) Remove blocks (22) and (23) from the oil

Using a forcing screw, remove 5 sleeves (16). pan, then remove relief valves (24) and
(25).
4. Oil pan
1) Sling transmission assembly (17) and re- 5. Check of operation of pistons
move oil pan (18). Using tool D1, blow air into the clutch ports and
check the operation of the pistons of No. 1, 2,
and 3 clutches. (Since you cannot check the
operation of the pistons of No. 2 and 3 clutches
directly, check it by movement of the discs or
plates.)
a The locations of the clutch ports are
shown below.
q No. 1 clutch port: (A)
q No. 2 clutch port: (B)
q No. 3 clutch port: (C)
a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/
cm²}
q Standard stroke of clutch No. 1 pis-
ton: 4.2 mm
2) Remove cover (19) from the oil pan, then
remove spring (20) and magnet assembly
(21).
HD465-7E0, HD605-7E0 19
6. No. 1 clutch plates 9. No. 1 clutch drum and piston

1) Using sling bolts, remove No. 1 clutch 1) Using hanging bolts, remove clutch No.
plates (26). drum (33) and piston (34) together, then
a There are 2 bolts installed from the separate them from each other.
transmission case side.
2) Remove seal rings (35) and (36) from pis-

2) Remove bearing (27) from No. 1 clutch ton (34).
plates.
10. Input shaft and No. 1 ring gear assembly

7. No. 1 clutch spring and guide 1) Sling the input shaft and remove the input
Remove spring (28) and guide (29). shaft and No. 1 ring gear assembly (37).
8. Discs, plates, and springs

Remove discs (30), plates (31), and spring
(32).
20 HD465-7E0, HD605-7E0
2) Pull up and remove No. 1 ring gear (38). 6) Remove inner race (44) from gear (43).
3) Remove seal rings (39) and (40) from the
input shaft.
7) Remove snap ring (45), then remove

bearing (46) from input shaft (47).
4) Remove inner race (41) from No. 1 ring
gear (38).
11. No. 2 clutch assembly

Lift off No. 2 clutch assembly (48).
5) Remove snap ring (42) and press down
and remove gear (43).
HD465-7E0, HD605-7E0 21
12. Disassembly of No. 2 clutch assembly 4) Housing assembly

1) Turn over No. 2 clutch assembly and 1] Remove seal rings (53) and (54).
remove housing (49). 2] Remove snap ring (55), bushing (56),
and ball (57).
a Take care not to lose ball (57).
3] Remove inner race (58) and bearing
(59).
2) Remove mounting bolts, cover (50), and

piston (51).
5) Remove snap ring (60) and ring gear (61).
3) Remove seal ring (52) from piston (51).
6) Remove discs (62), plates (63), and spring

(64).
7) Using sling bolts, remove drum (65).
22 HD465-7E0, HD605-7E0
8) Remove plates (66) from carrier (67). 3] Remove seal ring (73), inner race (74),
and bearing (75) from carrier (67).
9) Carrier assembly
1] Remove shaft (68). 13. Transmission case
a Take care not to lose ball (69). 1) Remove cage assembly mounting bolts
2] Remove planetary gears (70), thrust (76) and lift off transmission case (77) ver-
washer (71), and bearing (72). tically.
2) Remove the following parts from the trans-

mission case.
1] Remove the assembly of cage (78)
and bearings (79), then remove the
bearings from the cage.
2] Remove collars (80) and bearings
(81) from the case.
3] Remove seal ring (82) from the collar.
HD465-7E0, HD605-7E0 23
14. Check of operation of piston 16. No. 3 clutch drum, discs, and plates
Using tool D1, check the operation of pistons 1) Using hanging bolts, remove No. 3 clutch
of No. 4, 5, 6, and 7 clutches. drum (84), discs, plates, and spring
a Air pressure: together.
0.29 – 0.59 MPa {3 – 6 kg/cm²} 2) Remove discs (85), plates (86), and spring
Standard strokes of pistons (87).
Piston No. Stroke (mm)
4 4.8
5 5.5
6 5.0
7 5.0
17. No. 3 clutch ring gear

1) Remove No. 3 clutch ring gear (88).
2) Remove inner race (89) and seal ring (90)
from the ring gear.
15. No. 3 clutch housing assembly

Remove the housing mounting bolts and No. 3
a For disassembly, see Step 12, Disassem-
bly of no. 2 clutch assembly, 1) – 4). (No.
3 clutch assembly has the same structure
as No. 2 clutch assembly.)
24 HD465-7E0, HD605-7E0
18. Tie bolts 20. No. 4 clutch discs, plates, and springs
Remove tie bolts (91). Remove discs (96), plates (97) and (98), and
springs (99) and (100).
19. No. 4 clutch plates and sun gear a Distinguish plates (97) and (98) from each
1) Remove plates (92). other.
2) Remove snap ring (93) and sun gear (94). a Since springs (100) of a clutch line have a
part No. different from those of another
clutch line, store them for each clutch line.
3) Remove seal ring (95) from No. 4 sun

gear (94).
21. No. 4 housing, piston, and ring gear

1) Using hanging bolts, remove No. 4 hous-
ing (101), piston (102), and ring gear (103)
together.
a If the dowel pin is hard to remove and
it may cuff the housing, take care not
to cause damage.
HD465-7E0, HD605-7E0 25
2) Remove seal rings (104) and (105) from 23. No. 5 housing, piston, ring gear, and guide
No. 4 housing (101) and piston (102). pins
1) Using sling bolts, remove No. 5 housing
(110), piston (111), and ring gear (112)
together.
a If the dowel pin is hard to remove and
it may cuff the housing, take care not
to cause damage.
2) Remove guide pins (113).
22. No. 5 clutch discs, plates, and springs

Remove discs (106), plates (107), and springs
(108) and (109).
a Since springs (108) of a clutch line have a
part No. different from those of another
3) Remove seal rings (114) and (115) from

No. 5 housing (110) and piston (111).
4) Remove sleeve (116) for tie bolt (91) from

No. 5 housing and check the direction of
the sleeve (slit (A)).
26 HD465-7E0, HD605-7E0
24. No. 6 clutch discs, plates, and springs 26. Disassembly of No. 4 and No. 5 carriers as-
Remove discs (117), 4 plates (118) and (119), sembly
and springs (120) and (121). 1) Remove No. 5 sun gear (123).
a Since springs (120) of a clutch line
have a part No. different from those of
another clutch line, store them for
each clutch line.
a Distinguish plates (118) and (119)
from each other.
2) Turn over the carrier assembly and re-

move bearing (124) and seal ring (125).
3) Drive out shaft (126) toward the ball and

remove ball (127).
a Take care not to lose the ball.
4) Drive out shaft (126) from the ball side and
25. No. 4 and No. 5 carriers assembly remove No. 5 planetary gears (128), bear-
Using hanging bolts, remove No. 4 and No. 5 ing (129), collar (130), and thrust washer
carriers assembly (122). (131).
a At this time, 4 of 8 No. 5 planetary
gears come off.
HD465-7E0, HD605-7E0 27
5) Drive out shaft (132) toward No. 4 carrier 27. No. 6 and No. 7 housings, pistons, and
and remove ball (133). springs
a Take care not to lose ball (133). 1) Using sling bolts, remove No. 6 and No. 7
6) Drive out shaft (132) further and remove it. housings (139) and pistons (140) and
7) Remove No. 4 planetary gears (134), (141).
bearing (135), thrust washer (136), No. 5 a If the dowel pin is hard to remove and
planetary gear (128), bearing (129), collar it may cuff the housing, take care not
(130), and thrust washer (131). to cause damage.
8) Remove snap ring (137) and ring gear
(138).
2) Remove seal rings (142), (143), and (144)

from No. 6 and No. 7 housings (139) and
pistons (140) and (141).
28 HD465-7E0, HD605-7E0
28. No. 7 clutch discs, plates, and springs 30. Disassembly of No. 6 and No. 7 carriers as-
Remove discs (145), plates (146), and springs sembly
(147) and (148). 1) Remove collar (150).
a Since springs (148) of a clutch line have a 2) Remove inner race (151) and snap ring
part No. different from those of another (152) from collar (150).
3) Tighten forcing screws [1] to remove

plates (153).
4) Remove seal ring (154) and bearing (155)
from the plates.
29. No. 6 and No. 7 carriers assembly

Using sling bolts, sling the shaft and remove
No. 6 and No. 7 carriers assembly (149).
5) Remove intermediate shaft (156) and No.
6 sun gear (157) together.
6) Remove snap ring (158) and inner race
(159) from intermediate shaft (156).
HD465-7E0, HD605-7E0 29
7) Pull out shaft (160) and remove No. 6 31. Guide pins and No. 7 clutch ring gear
planetary gear (161), bearing (162), thrust 1) Remove guide pins (176).
washer (163), and ball (164). 2) Remove No. 7 clutch ring gear (177).
32. Cage assembly

8) After removing No. 6 planetary gear, drive 1) Using forcing screws [3], remove cover
out shaft (165), collar (166), inner race (179) from cage assembly (178).
(167), and ball (168), using drive shafts [2] 2) Remove seal ring (180) from the cover.
(14 mm or less in diameter and about 200 3) Remove bearing (181) from the cage.
mm in length).
a Hit both shafts evenly to drive out the
above parts gradually.
9) Remove seal ring (169) from collar (166).
10) Remove planetary gear No. 7 (170), bear-
ing (171), and thrust washer (172).
11) Remove snap ring (173), collar (174), and
ball (175).
30 HD465-7E0, HD605-7E0
33. Output shaft and cage assembly 4) Remove bearing (188) from output shaft
1) Remove mounting bolts (182) and output (187).
shaft and cage assembly (183).
a Since the whole transmission is being
disassembled now, the output shaft
and cage assembly are removed at
this time. You can remove only the
output shaft assembly for repair of a
leaking oil seal, etc., however, if you
remove the speedometer gear
(optional) in advance.
5) Remove oil seal (189) and bearing (190)

from cage (186).
2) Remove worm (184) and collar (185) from

the output shaft.
a The collar consists of 2 semicircular
pieces.
3) Support cage (186) and press the output

shaft (187) with a press to drive it out of
the bearing.
HD465-7E0, HD605-7E0 31
Assembly 1. Output shaft and cage assembly

a Clean the all parts and check them for dirt or 1) Install bearing (190) and oil seal (189) to
damage before installing. cage (186).
a Coat the sliding surfaces of each part with 2 Oil seal lip:
engine oil before installing. Silicone grease (ThreeBond 1855)

a Soak the discs in clean engine oil (EO-10CD) 2 Press fitting surface on cage side:
for at least 2 minutes. Gasket sealant (LG-5)

a Install each piston seal ring (a) of the clutch a After press fitting, wipe off the exces-
assembly with its pressure receiving side (side sive gasket sealant.
b) directed toward housing (c).
a Apply grease (G2-LI) to the periphery of the all
seal rings.
a When fitting a bearing by expansion fit, drop
engine oil (EO10-CD or EO30-CD) over it and
rotate it 10 turns before chilling it in dry ice, etc.
2) Press fit bearing (188) to output shaft

(187).
a Securely fit springs (A) of No. 4 – No. 7clutches

to the seats of the piston and housing.
3) Set output shaft (187) on the press stand

and press the inner race side of the bear-
ing to install cage (186).
32 HD465-7E0, HD605-7E0
4) Install collar (185) and worm (184) to the 3. Guide pins and No. 7 clutch ring gear
output shaft. 1) Install guide pins (176) to the cage.
a The collar consists of 2 semicircular 2) Install No. 7 clutch ring gear (177).
pieces.

5) Fit the O-ring to the cage and install output Install discs (145), plates (146), and springs
shaft and cage assembly (183). (147) and (148).
a Install the 4 discs and 3 plates.
a Securely fit springs (148) to the seats of
the housing.
2. Cage assembly
1) Using the push tool, press fit bearing (181)
to cage (178).
2) Install cover (179) to cage (178).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
3) Install seal ring (180) to cover (179).
2 Periphery of seal ring:
Grease (G2-LI)
HD465-7E0, HD605-7E0 33
5. No. 7 clutch piston 7. Assembly of No. 6 and No. 7 carriers as-

Install seal ring (142) to piston (141), then sembly
matching it to the springs. 1) Install bearing (171) to No. 7 planetary
a Install the seal ring as shown below. gear (170). Fit thrust washers (172) to
2 Periphery of seal ring: Grease (G2-LI) both sides of them and set them to the
carrier.
6. No. 6 and No. 7 housings and No. 6 piston 2) Press fit shaft (165) and set ball (168) to
1) Install seal rings (142), (143), and (144) to secure the shaft.
housing (139) and piston (140). a When press fitting the shaft, align it
a Install the seal rings as shown below. with the bearing and avoid hitting it
2 Periphery of seal ring: strongly so that the bearing cage will
Grease (G2-LI) not be deformed.
3) Install seal ring (169) to collar (166) and
press fit inner race (167).
Grease (G2-LI)
4) Install ball (175) and collar (174) to the
carrier and secure them with snap ring
(173).
5) Check that No. 7 planetary gear rotates
smoothly.
2) Using sling bolts, sling No. 6 and No. 7

housings (139), matching them to piston
(141).
a If the dowel pin is hard, drive it with a
plastic hammer.
34 HD465-7E0, HD605-7E0
6) Install bearing (162) to No. 6 planetary 12) Press fit bearing (155) to plate (153).
gear (161). Fit thrust washers (163) to a Securely press fit the bearing to the
both sides of them and set them to the specified stopper position.
carrier. 13) Install seal ring (154).
7) Drive shaft (160) and set ball (164) to 2 Periphery of seal ring:
secure the shaft. Grease (G2-LI)
a When driving the shaft, align it with 14) Install plate (153) to No. 6 and No. 7 carri-
the bearing and avoid hitting it ers.
strongly so that the bearing cage will 2 Mounting bolts: Adhesive (LT-2)
not be deformed. 3 Mounting bolt:
8) Check that No. 6 planetary gear rotates 58.8 – 73.5 Nm {6 – 7.5 kgm}
smoothly.
15) Install snap ring (152) to collar (150).

9) Press fit inner race (159) to intermediate a Check that the snap ring is fitted to
shaft (156). the collar groove.
10) Install snap ring (158). 16) Press fit inner race (151) to collar (150)
a Check that the snap ring is fitted to and install them to the intermediate shaft.
the groove.
11) Install No. 6 and No. 7 carrier intermediate
shaft (156) and sun gear (157).
HD465-7E0, HD605-7E0 35
8. No. 6 and No. 7 carriers assembly 6) Install ring gear (138) to the carrier and
Using sling bolts, sling the shaft. Install No. 6 secure it with snap ring (137).
and No. 7 carriers assembly (149), matching a Mesh the external teeth on the carrier
the gear to the bearing. side with the internal teeth on the ring
gear side, then align the carrier with
the ring gear so that the snap ring will
be inside the 45° chamfering diame-
ter of the ring gear.
a Check that the external teeth are
meshed with the internal teeth and
the whole snap ring is inside the
chamfering diameter of the ring gear,
then press in the ring gear until it is
locked.
a Check that the clearance between the
bottom of the external teeth of the
carrier and the inside diameter of the
fitted snap ring is 2.0 – 3.2 mm
9. Assembly of No. 4 and No. 5 carriers as-
through the circumference.
sembly
a Hold the ring gear and move it up and
1) Install bearing (135) to No. 4 planetary
down. Check that carrier does not
gear (134). Fit thrust washers (136) to
come off at this time.
both sides of them and set them to the
carrier.
2) Set collar (130) between 2 bearings (129)
and install them to No. 5 planetary gear
(128). Fit thrust washers (131) to both
sides of them and set them to the carrier.
3) Chill shaft (132) in dry ice, then install it to
the carrier.
a Check that the shaft, bearing, thrust
washers, and carrier are aligned and
take care that the bearing and thrust
washers will not be damaged.
a Match the ball fitting hole of the shaft
to the hole of the carrier.
4) Fit ball (133) and install shaft (132) se-
curely.
5) Check that the gear rotates smoothly.
36 HD465-7E0, HD605-7E0
7) Set collar (130) between 2 bearings (129) 10. No. 4 and No. 5 carriers assembly
and install them to No. 5 planetary gear Using hanging bolts, sling the shaft. Install No.
(128). Fit thrust washers (131) to both 4 and No. 5 carriers assembly (122), matching
sides of them and set them to the carrier. the gear to the bearing.
8) Drive shaft (126), matching the bearing to a You can install the "No. 4, No. 5 carriers,
the thrust washer. No. 6, and No. 7 assembly", too, as you
9) Drive out shaft (126) until the ball hole is removed. If this assembly is slung and
seen perfectly, then fit ball (127) and drive moved, however, the bearing in the inter-
the shaft into the carrier. mediate position may come off. Accord-
a When driving the shaft, align it with ingly, divide this assembly.
the bearing and avoid hitting it strong-
ly so that the bearing cage will not be
deformed.
a Check that the gear rotates smoothly.
11. No. 5 clutch sun gear

Install sun gear (123).
a Take care not to have your fingers caught
in the gears.
10) Install bearing (124) and seal ring (125) to
the carrier assembly.
Grease (G2-LI)
12. No. 4 clutch sun gear

1) Install seal ring (95) to gear (94).
Grease (G2-LI)
HD465-7E0, HD605-7E0 37
2) Install gear (94). 14. No. 5 housing, piston, ring gear, and guide
3) Install snap ring (93). pins
1) Install tie bolt sleeves (116) to No. 5 hous-
ing (110).
a When installing the sleeve, set slit (A)
at the position checked when re-
moved.
a When tie bolts (91) are installed, they
become hard because of the cushion
sleeves. At this time, do not drive
them forcibly with a hammer. (For
prevention of breakage)

Install plate (119), discs (117), plates (118),
and springs (120) and (121).
a Install the 4 discs, 4 plates (118), and 1
plate (119).
a Install one of plates (118) on the top.
a Check that springs (120) are fitted to the
seats of the piston and housing.
a Securely install 6 springs (121) to each
disc.
2) Install seal rings (114) and (115) to hous-
ing (110) and piston (111), then install the
piston to the housing.
a Install the seal ring as shown in the
following figure.
Grease (G2-LI)
38 HD465-7E0, HD605-7E0
3) Set No. 5 clutch ring gear (112). 16. No. 4 housing, piston, and ring gear
a Set the gear with the chamfered side 1) Install seal rings (104) and (105) to hous-
up. ing (101) and piston (102), then install the
4) Using hanging bolts, install No. 5 housing piston to the housing.
(110), matching it to the spring. a Install the seal rings as shown below.
a If the dowel pin is hard, drive it with a 2 Periphery of seal ring:
plastic hammer. Grease (G2-LI)
5) Install guide pins (113).
2) Using sling bolts, install No. 4 housing

15. No. 5 clutch, discs, plate, and springs (101), matching it to the spring.
Install discs (106), plate (107), and springs a Check that the springs are fitted to
(108) and (109). the seats of the piston and plate.
a Install the 5 discs and 4 plate. a If the dowel pin is hard, drive it with a
a Securely install 6 springs (109) to each plastic hammer.
disc. 3) Install ring gear (103).
a Set the gear with the chamfered side
up.
HD465-7E0, HD605-7E0 39
17. No. 4 clutch, discs, plate, and springs 18. No. 4 clutch plate
Install plate (98), discs (96), plates (97), and Install plate (92).
springs (99) and (100). a Check that the springs are fitted to the
a Install the 4 discs, 3 plates (97), and 1 seats of the piston and plate.
plate (98).
a Securely install 6 springs (99) to each 19. Tie bolts
disc. Install tie bolts (91).
a Press in each bolt to the end of the cup
hole. Do not use a hammer at this time.
a Do not use an impact wrench until the bolt
catches the threads.
3 Tie bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
20. No. 3 clutch ring gear

1) Install inner race (89) and seal ring (90) to
the ring gear.
Grease (G2-LI)
40 HD465-7E0, HD605-7E0
2) Install No. 3 clutch ring gear (88). a If the pistons do not move smoothly, apply
2 Mounting bolt: Adhesive (LT-2) engine oil to them.
3 Mounting bolt:
156.9 – 196 Nm {16 – 20 kgm}
23. Transmission case

1) Install the following parts to the transmis-
21. No. 3 clutch housing assembly sion case.
a For sassembly, see Step 24, assembly of 1] Install seal ring (82) to the outer
No. 2 clutch assembly, 5) – 8). (No. 3 groove of collars (80), then install
clutch assembly has the same structure them, matching to the dowel pin of
as No. 2 clutch assembly.) the transmission case.
a The plates, discs, and springs are each 1 2 Periphery of seal ring:
less than those of No. 2 clutch assembly. Grease (G2-LI)
a Using hanging bolts, sling and install 2] Install cage (78).
housing assembly (83), matching the in- 3] Install bearings (79) and (81) to both
ternal teeth of the disc to the external sides.
teeth of the ring gear. a Press fit the bearings until they
2 Mounting bolt: Adhesive (LT-2) are stopped by collars (80).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
22. Check of operation of piston

Using tool D1, check the operation of pistons
of No. 4, 5, 6, and 7 clutches.
a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/
cm²}
Standard stroke of piston
Piston No. Stroke (mm)
4 4.8
5 5.5
6 5.0
7 5.0
HD465-7E0, HD605-7E0 41
2) Install the O-ring to the transmission case. 2] Install bearing (72) to planetary gear
3) Sling and install transmission case (77) (70). Fit thrust washers (71) to both
and tighten cage assembly mounting bolts sides of them and set them to the car-
(76). rier.
3] Matching the thrust washer to the
bearing, drive shaft (68).
a When driving the shaft, align it
with the bearing and avoid hitting
it strongly so that the bearing
cage will not be deformed.
4] Fit ball (69) and install shaft (68)
securely.
a If the shaft moves out, caulk the
carrier side with a punch.
a Check that the gear rotates
smoothly.
24. Assembly of No. 2 clutch assembly

1) Carrier assembly
1] Install inner race (74), bearing (75),
and seal ring (73) to carrier (67).
Grease (G2-LI)
2) Install plate (66) to carrier (67).

3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
42 HD465-7E0, HD605-7E0
3) Turn over the carrier assembly. Using 6) Housing assembly

sling bolts, install drum (65), matching it to 1] Install inner race (58) and bearing
the gear of the carrier. (59) to the housing.
2] Install ball (57) and bushing (56), then
secure them with snap ring (55).
3] Install seal rings (53) and (54).
a Install the seal rings as shown
below.
Grease (G2-LI)
4) Install the ring gear (61), matching it to the

carrier, and secure it with snap ring (60).
5) Discs, plates, and springs
Install discs (62), plates (63), and springs
(64) between the drum and ring gear.
a Install the 5 discs, 4 plates, and 5
springs.
7) Install seal ring (52) to piston (51).
a Install the seal ring as shown below.
Grease (G2-LI)
HD465-7E0, HD605-7E0 43
8) Install piston (51) to the housing, then 26. Input shaft and No. 1 ring gear assembly
install cover (50). 1) Press fit bearing (46) to input shaft (47)
2 Mounting bolt: Adhesive (LT-2) and install snap ring (45).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Install inner race (44) to gear (43).
9) Install housing (49) to the drum.

3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
3) Install gear (43) to the outer race side of

the bearing, then install snap ring (42).
25. No. 2 clutch assembly

Using sling bolts, sling and install No. 2 clutch
assembly (48), matching the external teeth of
the piston to the internal teeth of the drum.
44 HD465-7E0, HD605-7E0
4) Install inner race (41) to No. 1 ring gear 27. No. 1 clutch, drum, and piston
(38). 1) Install seal rings (35) and (36) to piston
(34), then install them to the drum (33).
a Install the seal rings as shown below.
Grease (G2-LI)
2) Using sling bolts, install No. 1 clutch drum
(33) and piston (34) together.
5) Install ring gear (38) and seal rings (39)

and (40) to the input shaft.
Grease (G2-LI)
6) Sling the input shaft and install the input

shaft and No. 1 ring gear assembly (37),
matching the gear to the bearing. 28. No. 1 clutch discs, plates, and springs
Install discs (30), plates (31), springs (28) and
(32), and guide (29).
a Install the 3 discs and 2 plates.
HD465-7E0, HD605-7E0 45
29. No. 1 clutch plate 30. Check of operation of piston

1) Install bearing (27) to No. 1 clutch plate. Using tool D1, blow air into the clutch ports and
check the operation of the pistons of No. 1, 2,
and 3 clutches. (Since you cannot check the
operation of the pistons of No. 2 and 3 clutches
directly, check it by movement of the discs or
plates.)
a The locations of the clutch ports are
shown below.
q No. 1 clutch port: (A)
q No. 2 clutch port: (B)
q No. 3 clutch port: (C)
a Air pressure:
0.29 – 0.59 MPa {3 – 6 kg/cm²}
q Standard stroke of clutch No. 1 piston
4.2 mm
2) Using sling bolts, install plate (26), match-
ing it to the spring and guide.
3 Mounting bolt:
156.9 – 196 Nm {16 – 20 kgm}
31. Oil pan

1) Install relief valves (24) and (25) to the oil
pan, then install blocks (22) and (23).
46 HD465-7E0, HD605-7E0
2) Install magnet assembly (21) and spring 33. Control valve assembly
(20) to the oil pan, then fit the O-ring and 1) Install each control valve (14) to the valve
install cover (19). seat.
3 Control valve:
8.0 – 10.0 Nm {0.8 – 1.0 kgm}
2) Install filter assembly (15).
a If the filter case and filter bracket plug
were removed, tighten them to the fol-
lowing torque.
3 Filter case:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3 Plug:
15.7 – 19.2 Nm {1.6 – 2.0 kgm}
3) Install sling bolts to (A), then install the
valve seats and control valve assembly
(13) together.
2 Mounting bolt:
3) Fit the plate gasket to oil pan (18) horizon-
tally, then sling and install transmission
4) Install wiring harness (12) and connect the
assembly (17).
2 Both sides of plate gasket:
connectors to each control valve.
5) Install tube (11) and cover (10).

32. Sleeve
Fit the O-rings to sleeves (16) and install them
to the transmission.
HD465-7E0, HD605-7E0 47
34. Sensors, wiring harness, covers, and trans-

mission mounts
1) Install block (9).
2) Install lubricating oil temperature sensor
(8) and cover (7).
3) Install output shaft speed sensor (6), inter-

mediate shaft speed sensor (5), and input
shaft speed sensor (4).
a For installation procedure, see Test-
ing and adjusting, Adjusting transmis-
sion speed sensors.
4) Install covers (2) and (3).

5) Install both transmission mounts (1).
48 HD465-7E0, HD605-7E0
Removal and installation of Installation

transmission control valve q Carry out installation in the reverse order to
assembly (ECMV assembly) 1 removal.
Removal [*1]
k
Before removing the Transmission control valve
assembly, clean the area around the valve thor-
k
oughly, and make sure that no dirt or dust gets in.
Raise the dump body and lock with the
safety pin.
k
[*2]
3
Disconnect the cable fro the negative (–)
ECMV assembly mounting bolt:
7.85 – 9.81 Nm {0.8 – 1.0 kgm}
1. Remove cover.
2. Disconnect wiring connectors (1) and (2).
3. Remove transmission control valve assembly

(3). [*1] [*2]
a Only 1 wiring connector is used for the
lockup clutch ECMV assembly.
HD465-7E0, HD605-7E0 49
Disassembly and assembly of transmission control valve assembly

(ECMV assembly) 1
Disassembly
q Before removing the ECMV assembly from the 3. Pressure control valve
transmission assembly, clean around it thor- 1) Remove solenoid valve (12).
oughly so that dirt will not enter it or transmis- 2) Remove valve (14) and ball (13).
sion. 3) Remove spool (15), shims (16) and (17)
q Keep the removed parts so that they will not be and spring (18).
damaged. a Check the quantity and thickness of
the shims.
1. Remove plug (2) and spool (3) from valve body
(1).
a When disassembling the valve, check that
the spool moves smoothly.
2. Flow sensor valve

1) Remove bracket (4) and fill switch assem-
bly (5).
2) Remove spring (6) and shims (7) and (8).
a Check the quantity and thickness of
the shims.
3) Remove seat (9), spring (11) and pin (10).
50 HD465-7E0, HD605-7E0
Assembly 2. Flow sensor valve

1) Install pin (10) and spring (11) to seat (9).
a If the pressure control section was disassem- 2) Fit the O-ring to plug (2), install spool (3)
bled or any part in it was replaced, be sure to to valve body (1), and install plug (2).
2 O-ring: Grease (G2-L1)
check the oil pressure.
3 Plug:
a Clean all the parts and check them for dirt or
damage. Coat their sliding surfaces with axle 127.4 ± 12.7 Nm {13.0 ± 1.3 kgm}
oil before installing. 3) Install seat (9), shims (8) and (7) and
spring (6) to valve body (1).
1. Pressure control valve q Standard number of shims: 2
1) Install shims (10) and (11) and spring (12) q Standard thickness of shims: 1.0 mm
to spool (9). (Thickness of 1 shim: 0.5 mm)
q Standard number of shims: 3 q Kinds of shims: 0.2, 0.5 mm
q Standard thickness of shims: 1.5 mm 4) Install switch assembly (5) and bracket
(Thickness of 1 shim: 0.5 mm) (4).
3 Mounting bolt:
q Kinds of shims: 0.2, 0.5 mm
2) Install ball (13) and O-ring to valve (14). 4.9 ± (+2/0) Nm {0.5 ± (+0.2/0) kgm}
3) Install spool (15) to valve body (1). 3. Measuring of ECMV oil pressure
4) Install valve (14) to: solenoid valve (12). Measure the ECMV oil pressure. For details,
3 Valve:
see Testing and adjusting, "Measuring ECMV
19.6 ± (+2.0/0) Nm {2.0 ± (0.2/0) kgm} oil pressure".
5) Fit the O-ring to solenoid valve (12) and
install them to valve body (1). 4. Adjusting ECMV oil pressure
Adjust the ECMV oil pressure. For details, see
3 Solenoid valve:
Testing and adjusting, "Adjusting ECMV oil
49.0 ± 5.0 Nm {5.0 ± 0.5 kgm} pressure".
a When installing the solenoid valve,
check the solenoid ID No. 425 (part
a).
a When reusing all of solenoid valve

(12), valve (14), spool (15) and spring
(18), insert the shims of the number
checked when disassembled.
a When replacing solenoid valve (12),
check that spring (18) is installed
securely.
HD465-7E0, HD605-7E0 51
ECMV for lockup clutch

Disassembly
q Before removing the ECMV assembly from the

transmission assembly, clean around it thor-
oughly so that dirt will not enter it or transmis-
sion.
q Keep the removed parts so that they will not be
damaged.
1. Remove bracket (2) and plate (3) from valve

body (1).
a When disassembling the valve, check that
the spool moves smoothly.
2. Remove seat (4) and sleeve (5).

1) Remove solenoid valve (6).
2) Remove valve (8) and ball (7).
3) Remove spool (9), shims (10) and (11)
and spring (12).
a Check the quantity and thickness of
the shims.
52 HD465-7E0, HD605-7E0
ECMV for lockup clutch 6) Install sleeve (5) and seat (4) to valve
Assembly body (1).
a If the pressure control section was disassem-
bled or any part in it was replaced, be sure to 7) Fit the O-ring to valve body (1) and then
check the oil pressure. install plate (3) and bracket (2).
a Clean all the parts and check them for dirt or 3 Mounting bolt:
damage. Coat their sliding surfaces with axle 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
oil before installing.

1) Install shims (10) and (11) and spring (12)
to spool (9).
q Standard number of shims: 3
q Standard thickness of shims: 1.5 mm
(Thickness of 1 shim: 0.5 mm)
q Kinds of shims: 0.2, 0.5 mm
2) Install ball (7) and O-ring to valve (8).
3) Install spool (9) to valve body (1).
4) Install valve (8) to solenoid valve (6).
3 Valve:
19.6 ± (+2.0/0) Nm {2.0 ± (0.2/0) kgm}
5) Fit the O-ring to solenoid valve (6) and
install them to valve body (1).
3 Solenoid valve:
49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}
a When installing the solenoid valve,
check the solenoid ID No. 425 (part
a).
a When reusing all of solenoid valve

(12), valve (14), spool (15) and spring
(18), insert the shims of the number
checked when disassembled.
a When replacing solenoid valve (12),
check that spring (18) is installed
securely.
HD465-7E0, HD605-7E0 53

© 2007 KOMATSU
All Rights Reserved
54 HD465-7E0, HD605-7E0
SEN02486-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Power train, Part 2
Removal and installation of differential assembly ........................................................................................... 2
Disassembly and assembly of differential assembly....................................................................................... 4
Removal and installation of final drive carrier assembly ............................................................................... 16
Disassembly and assembly of final drive carrier assembly........................................................................... 17
Disassembly and assembly of front wheel hub assembly............................................................................. 18
HD465-7E0, HD605-7E0 1
Removal and installation of 5. Remove guard (3) and drive shaft (4). [*2]
differential assembly 1 6. Disconnect hoses (5), (6), and (7) and remove
slack adjuster (8).
Removal
k Apply the parking brake and put blocks
under the wheels.
1. Remove the dump body assembly. For details,

see "Removal and installation of dump body
assembly".
2. Drain oil from the differential case and final

drive case. [*1]
6 Differential case: 95 l
6 Final drive case (Each side): 21 l
3. Using guide bolts [1], remove cover (1). (The

rear wheel assembly is removed in the follow- 7. Using forcing screws [2] and guide bolt [3], pull
ing photo. It does not need to be removed, out differential assembly (9) forward. [*3]
4 Differential assembly: 800 kg
however.)
4. Pull out drive shaft (2).

a Install a hanging bolt to the shaft end to
pull out the shaft.
2 HD465-7E0, HD605-7E0
Installation
removal.
[*1]
3 Drain plug
(Center of cover on final drive case side):
127.4 – 176.4 Nm {13.0 – 17.9 kgm}
(Periphery of cover on final drive case side):
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
[*2]
a Before tightening the bolts, check that the key
way of the spider cap is fitted to the key way of
the mating yoke.
3 Mounting bolt:
157 – 196 Nm {16.0 – 19.9 kgm}
[*3]
3 Mounting bolt:
490 – 605 Nm {50.0 – 61.7 kgm}
Refilling with oil

5 Differential case: 95 l (EO30-CD)
5 Final drive case (Each side):

21 l (EO30-CD)
HD465-7E0, HD605-7E0 3
Disassembly and assembly of 4. Bevel pinion and cage assembly

1) Lift off bevel pinion and cage assembly
differential assembly 1 (5).
a Before removing the bevel pinion and
Special tools
cage assembly, make match marks
on the cage and differential case.
New/Remodel
a Check the thickness, quantity, and
Necessity
Sym-
Part No. Part name location of shim (6).
Sketch
bol
Q'ty
1 790-901-5110 Bracket t 1
790-901-3420 Plate t 1
H
2 790-425-1660 Wrench t 1
3 790-102-1130 Power wrench t 1
4 797-101-1171 Power wrench t 1
Disassembly
1. Tool of differential assembly
Set the differential assembly to tool H1.
2) Using press [2], press down bevel pinion
2. Coupling assembly (7) and remove it and bearing
Remove holder (1) and coupling (2). (8) together from cage assembly (9).
a Set a block, etc. under the bevel pin-
ion assembly to prevent the assembly
from falling to the floor.
3. Cage
1) Using forcing screws [1], remove cage (3).
a Before removing the cage, make
match marks on it and differential
case.
2) Remove oil seal (4) from cage (3).
4 HD465-7E0, HD605-7E0
3) Disassembly of bevel pinion assembly

Remove spacer (11) and bearing (12)
from bevel pinion assembly (10).
4) Disassembly of cage assembly

Remove outer races (14) and (15) from
cage (13).
4) Sling differential gear assembly (20) tem-

porarily.
5) Using tool H3, remove 4 bearing cap bolts
(21).
6) Remove bearing caps (22) and (23) and
adjustment nuts (18) and (19).
5. Removal of differential gear assembly

1) Turn over tool H1.
2) Remove locks (16) and (17).
3) Using tool H2, loosen adjustment nuts
(18) and (19) until you can turn them with
the hand.
HD465-7E0, HD605-7E0 5
7) Remove outer races (24) and (25) from 3) Remove bearing (29) from case (27).
both bearings and lift off differential gear
assembly (20).
4) Remove side gear (30).
6. Disassembly of differential gear assembly

1) Lift off case and bearing assembly (26).
a Before removing the assembly, make
match marks on the top and bottom of
the case.
5) Remove cross shaft and pinion gear

assembly (31).
2) Remove washer (28) from inside of case

(27).
6 HD465-7E0, HD605-7E0
6) Remove pinion gear assembly (33) from 10) Remove washer (38).
cross shaft (32).
11) Turn over the case and bevel gear assem-

7) Using tool H4, remove nut (34). bly.
8) Remove sleeve (35) and the bearing. 12) Remove bevel gear (39) from case (40).
a The bearing is an assembly of large a Before removing the bevel gear, make
bearing (A), small bearing (B), outer match marks on it and the case.
r ace spac er (C), and i nner r ace 13) Remove bearing (41).
spacer (D).
9) Remove side gear (37).
HD465-7E0, HD605-7E0 7
Assembly a After installing the washer, check that

a Clean the all parts and check them for dirt or distance (a) between the washer sur-
damage. face and the end of dowel pin (E) is
a Coat the sliding surfaces with engine oil 0.35 – 0.75 mm. (If the dowel pin has
(EO30-CD) before installing. been removed, drive it to the above
dimension.)
1. Assembly of differential gear assembly
1) Install bearing (41) to case (40) by shrink
fit.
a Shrink fit temperature of bearing:
Keep at 120°C for 30 min.
a After installing the bearing, drop
engine oil (EO30-CD) over it.
2) Install bevel gear (39) to case (40).
a When installing, match the match
marks.
3 Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
5) Install side gear (37).
3) Turn over the case and bevel gear assem-

bly.
4) Install washer (38).
a Install the washer with the grooved
side up.
8 HD465-7E0, HD605-7E0
6) Install the bearing to the pinion gear. 10) Install cross shaft and pinion gear assem-
a Drop engine oil (EO30-CD) over the bly (31).
sliding parts.
a The bearing is an assembly of large
bearing (A), small bearing (B), outer
r ace spac er (C), and i nner r ace
spacer (D).
a Do not change the combination of the
above parts. (The same combination
mark is stamped on each part.)
7) Install sleeve (35) as shown in the follow-
ing figure.
8) Using tool H4, tighten nut (34).
3 Nut:
490 – 408 Nm {50.0 – 61.9 kgm}
a After tightening the nut, rotate the
11) Install side gear (30).
bearing 5 turns or more to check that
it rotates lightly.
12) Install bearing (29) to case (27) by shrink

fit.
9) Install pinion gear assembly (33) to cross
a Shrink fit temperature of bearing:
shaft (32).
Keep at 120°C for 30 min.
a After installing the bearing, drop en-
gine oil (EO30-CD) over it.
HD465-7E0, HD605-7E0 9
13) Turn over case (27) and install washer 2. Installation of differential gear assembly
(28). 1) Sling differential gear assembly (20) to the
a Install the washer with the grooved installation position of the differential case.
side up. a Keep the differential gear assembly
above the differential case.
2) Install outer races (24) and (25) to both
bearings.
a Drop sufficient amount of engine oil
(EO30-CD) over the bearings.
3) Install adjustment nuts (18) and (19) to the
differential case temporarily.
a After installing the washer, check that

distance (a) between the washer sur-
face and the end of dowel pin (E) is
0.35 – 0.75 mm. (If the dowel pin has
been removed, drive it to the above
dimension.)
4) Install bearing caps (22) and (23).

5) Using tool H3, tighten 4 bearing cap bolts
(21).
a Before tightening the bearing cap
bolts, rotate the bevel gear 20 – 30
turns to fit the bearing.
3 Mounting bolt:
2,450 – 3,040 Nm {249.9 – 309.9 kgm}
a Before installing the locks for fixing
the adjustment nuts, finish the follow-
ing "Adjusting preload on bearing",
"Adjusting backlash", "Testing tooth
14) Sling and install case and bearing assem-
contact", and "Adjusting tooth con-
bly (26).
tact".
marks.
10 HD465-7E0, HD605-7E0
4. Bevel pinion and cage assembly

1) Assembly of cage assembly
Install outer races (14) and (15) to cage
(13).
a Press fit the outer races until they are
stopped by the cage.
3. Adjusting preload on bearing

Press push-pull scale [3] against the periphery
of bevel gear (39) and measure the starting
tangential force in the tangential direction.
q Standard starting tangential force:
39.2 – 62.8 N {4.0 – 6.4 kg} 2) Assembly of bevel pinion assembly
[Target: 51.0 N {5.2 kg}] 1] Install bearing (12) to bevel pinion
a If the starting tangential force is below the (10) by shrink fit or press fit it to the
standard value, tighten the adjustment end with the push tool.
nuts on both sides with tool H2. If the a Shrink fit temperature of bear-
former exceeds the standard value, ing: Keep at 120°C for 30 min.
loosen the adjustment nuts on both sides. a After installing the bearing, drop
a When adjusting, rotate the bevel gear so engine oil (EO30-CD) over it.
that the bearings will be fitted sufficiently. 2] Install spacer (11).
Reference: This spacer is a part of
cage assembly (13) shown
above.
HD465-7E0, HD605-7E0 11
3) Place cage assembly (9) on bevel pinion 5. Cage

assembly (7). 1) Install oil seal (4) to cage (3).
4) Install bearing (8). a Press fit the oil seal until it is stopped
5) Using push tool [4] and revolving cage by the cage.
assembly (9), press fit bearing (8) to the 2 Outer ring of oil seal:
end. SEALEND 242 or equivalent
a Drop engine oil (EO30-CD) over bear- 2 Lip of oil seal: Grease (G2-LI)
ing (8). 2) Fit the O-ring and cage (3).
a Do not use a press to press fit the a When installing, match the match
bearing. marks.
6) Hold bevel pinion assembly (7) and re- 3 Mounting bolt:
volve cage assembly (9) with the push-pull 455 – 565 Nm {46.4 – 57.6 kgm}
scale and measure the starting tangential
force in the tangential direction.
q Standard starting tangential force:
Max. 24.5 N {2.5 kg}
a If the starting tangential force ex-
ceeds the standard value, replace
bearings (8) and (12) or cage assem-
bly (9) and measure again. Check
that the starting tangential force is in
the standard range.
3) Set dial gauge [5] on the top of bevel pin-

ion assembly (7). Move the bevel pinion
assembly in the thrusting direction and
measure the end play.
q Standard end play: 0 – 0.15 mm
a If the end play exceeds the standard
value, replace bearings (8) and (12)
or cage assembly (9) and measure
again. Check that the end play is in
the standard range.
7) Install shim (6) of the thickness and quan-
tity checked when disassembled. Fit the
O-ring and sling and install bevel pinion
cage assembly (5).
q Thicknesses of shims:
0.2 mm, 0.3 mm, 1.0 mm
marks.
12 HD465-7E0, HD605-7E0
6. Coupling 3) If the backlash is out of the standard

1) Install coupling (2), O-ring, and holder (1). range, adjust it by moving the bevel gear.
a Rotate the bevel gear to rotate the a Move the bevel gear with tool H2 and
bevel pinion 20 – 30 turns and tighten adjustment nuts (18) and (19).
the mounting bolts gradually. a If either adjustment nut is tightened
2 Mounting bolt: Adhesive (LT-2) (loosened), loosen (tighten) the other
3 Mounting bolt: adjustment nut by the same angle so
1,520 – 1,910 Nm {155.0 – 194.7 kgm} that the preload applied to bearings
2) Rotate the coupling 20 – 30 turns, and (29) and (41) (in Step 3) will not
then check that the holder mounting bolts change.
are tightened to the specified torque.
7. Adjusting backlash
1) Apply the probe of dial gauge [5] to a tooth
tip of the bevel gear at right angles.
2) Fix the bevel pinion and move the bevel
gear forward and backward (in the revolv-
ing directions) and read the dial gauge.
q Standard backlash: 0.41 – 0.56 mm
a Measure the backlash at 3 – 4 places
and check that the difference be-
tween the measured values is 0.1 mm
or less.
HD465-7E0, HD605-7E0 13
q When the backlash is below stan- 9. Adjusting tooth contact

dard value If the tooth contact pattern is not proper, adjust
Loosen adjustment nut (19) on the the tooth contact according to the procedure
bevel gear side and tighten adjust- shown in the following page.
ment nut (18) on the right side by the a Adjust the toot contact by increasing or
same angle (to move the bevel gear decreasing shim (6) (to move the bevel
in the direction of (A)). pinion) and revolving the adjustment nuts
q When the backlash is above stan- (to move the bevel gear: See Adjusting
dard value backlash).
Loosen adjustment nut (18) on the a After adjusting the tooth contact, check
right side and tighten adjustment nut the backlash again.
(19) on the bevel gear side by the
same angle (to move the bevel gear
in the direction of (B)).
8. Testing tooth contact

Apply red lead thinly to the surfaces of 7 – 8
teeth of the bevel gear and turn the bevel gear
in the forward and reverse directions, then
check the tooth contact pattern on the bevel
gear.
a The center of the tooth contact must be as
follows.
q Middle of tooth height
q Point on tooth at distance of (x) from
small end (C)
(x = 46 ± 6 mm)
a Width (y) of the tooth contact must be 41 –
82 mm.
a Check that there is not a strong contact at
tip (A), bottom (B), small end (C), or large
end (D).
14 HD465-7E0, HD605-7E0
Tooth contact Cause Adjusting method
1. Reduce shim (6) to move

Bevel pinion is too far
bevel pinion close to bevel
from bevel gear.
gear.
2. Move bevel gear away from
bevel pinion.
1. Increase shim (6) to move

Bevel pinion is too
bevel pinion away from bevel
close to bevel gear.
gear.
2. Move bevel gear close to
bevel pinion.
1. Reduce shim (6) to move

Bevel gear is too
bevel pinion close to bevel
close to bevel pinion.
gear.
2. Move bevel gear away from
bevel pinion.
1. Increase shim (6) to move

Bevel gear is too far
bevel pinion away from bevel
from bevel pinion.
gear.
2. Move bevel gear close to
bevel pinion.
10. Locks
Install locks (17) and (16) of the adjustment
nuts.
HD465-7E0, HD605-7E0 15
Removal and installation of final 5. Using guide bolts [2] and forcing screws [3],
pull out and remove carrier assembly (6).
drive carrier assembly 1 a When the carrier assembly comes off the
guide bolts, it is unbalanced suddenly.
Removal
Accordingly, insert a bar in the center shaft
q The rear wheel assembly is removed in the fol-
hole to balance the carrier assembly.
4 Carrier assembly: 230 kg
lowing photo. It does not need to be removed,
however.
1. Remove the drain plug of the cover and drain

oil from the final drive case. [*1]
6 Final drive case: 32 l (Each side)
2. Using guide bolts [1], remove cover (1).
Installation
removal.
[*1]
3 Drain plug
3. Pull out drive shaft (2). (Center of cover on final drive case side):
a Install a sling bolt to the shaft end to pull 127.4 – 176.4 Nm {13.0 – 17.9 kgm}
out the shaft. (Periphery of cover on final drive case side):
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
4. Remove snap ring (3), sun gear (4), and spac- [*2]
3
er (5). Carrier assembly mounting bolt:
490 – 608 Nm {50 – 62 kgm}
q Refilling with oil

5 Final drive case (Each side):
32 l (EO30-CD)
16 HD465-7E0, HD605-7E0
Disassembly and assembly of Assembly

final drive carrier assembly 1 1. Install bearing (4) to planetary gear (3).
Disassembly 2. Set planetary gear (3) to the case.

1. Drive out shaft (1) by hitting it outward. a Securely match the planetary gear to the
a Take care not to lose ball (2). hose on the case side.
2. Remove planetary gear (3) and bearing (4). 3. Matching the ball hole of shaft (1) to the cut for
the ball on the case side, press fit the shaft
until the ball hole comes in contact with the
case end.
4. Install ball (2) and press fit shaft (1) to the end.
HD465-7E0, HD605-7E0 17

front wheel hub assembly 1
Disassembly
1. Front brake calipers assembly
Remove the front brake calipers assembly. For
details, see Removal and installation of front
brake calipers.
2. Cover
Remove cover (1).
3. Wheel hub assembly

1) Support wheel hub assembly (2) with a
forklift. 5) Disassemble wheel hub assembly accord-
2) Remove retainer (3). ing to the following procedure.
a Check the quantity of the shims and 1] Remove the mounting bolts and
store them. brake disc (5).
2] Remove oil seal (6).
3] Remove outer race (7).
4] Remove outer race (8).
4. Bearing and retainer

1) Remove bearing (10).
2) Remove retainer (11).
3) Slant wheel hub assembly (2) lightly from

the rear and press it and bearing (4) out
together.
4) Remove bearing (4) and wheel hub as-
sembly (2).
4 Wheel hub assembly: 330 kg
18 HD465-7E0, HD605-7E0
Assembly
1. Retainer and bearing

1) Install retainer (11).
2) Install bearing (10).
4] Set brake disc (5) and tighten the

mounting bolts.
2) Support and install wheel hub assembly
(2) with a forklift.
1) Assemble the wheel hub assembly ac-
cording to the following procedure.
1] Using the push tool, press fit outer
race (8).
2] Using the push tool, press fit outer
race (7).
3] Using the push tool, press fit oil seal
(6).
a Degrease the sealing side of
wheel hub (A) and periphery of
the seal.
a Degrease part (B).
2 Periphery of seal:
2 Fill the shaded parts in the follow-
Adhesive: (LOCTITE No. 648) ing figure with sufficient amount of
2 Space c of seal lip:
grease. (Grease: 9 l for each wheel
Fill with grease (See Table 1). hub assembly)
a Take care not to damage the oil seal
Table 1 on the inside of the hub.
No. Manufacturer Brand of grease a Select the grease from Table 1.
1 NIHON KOYU HIREX HD-2
2 SHELL OIL Super Duty Grease 2 Table 1
No. Manufacturer Brand of grease
3 ESSO OIL RONEX MP
1 NIHON KOYU HIREX HD-2
4 BP Energrease LS-EP2
2 SHELL OIL Super Duty Grease 2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
HD465-7E0, HD605-7E0 19
a Fill the hatched space between the

rollers of the bearing until it is pro-
jected from the opposite side of the
retainer.
5) Install the shims and retainer (3). Revolv-

ing the hub 20 – 30 turns, tighten the bolts
evenly to the specified torque..
3) Install bearing (4). 3 Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
a After tightening the bolts, rotate the
hub and check that it rotates normally.
4) Adjust the preload on the bearing accord-

1] Install retainer (3) without inserting
any shim with 3 mounting bolts. 3. Cover
Revolving the hub 20 – 30 turns, Fit the O-ring and install cover (1).
tighten the bolts evenly to the speci- 3 Fill the inside of cover (hatched part)
fied torque. with grease.

3 Mounting bolt (For adjustment): a Use grease of the brand used for the
103 – 113 Nm {10.5 – 11.5 kgm} wheel hub in 2-2).
2] Measure distance (c) between the
retainer and axle end with depth
micrometer [1].
a Measure at 2 places and obtain
the average.
3] Remove retainer (3) and measure its
thickness (T). Add 0.3 mm to the dif-
ference between above distance (c)
and thickness (d) ((c) – (T)), then use
the result as the shim thickness.
a Measure at 2 places and obtain
the average.
a Combine the shims so that their
quantity will be minimum. 4. Front brake calipers assembly
a When removing the retainer, take Install the front brake calipers assembly. For
care that the bearing will not details, see "Removal and installation of front
come off. brake calipers".
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21

© 2007 KOMATSU
All Rights Reserved
22 HD465-7E0, HD605-7E0
SEN02487-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Steering system
Disassembly and assembly of steering cylinder assembly ............................................................................. 2
HD465-7E0, HD605-7E0 1

steering cylinder assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-502-1003 Repair stand t 1
1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench t 1
3 790-302-1270 Socket t 1
4. Remove cylinder (4) from tool U1.
790-101-1771 • Push tool KIT 1 5. Disassembly of piston rod assembly
4
790-101-5021 • Grip 1 1) Set tool U1 to piston rod assembly (3).
U 01010-50816 • Bolt 1 2) Using tool U3, remove nut (5).
a Width across flats of nut: 50 mm
790-101-1580 • Push tool KIT 1
5
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 790-720-1000 Expander t 1
7 796-720-1650 Ring t 1
8 07281-01029 Clamp t 1
Disassembly
1. Set cylinder assembly (1) to tool U1.
2. Raise the lock of the cylinder head nut. Using

3) Remove piston assembly (6) and cylinder
tool U2, remove cylinder head assembly (2).
head assembly (7) from rod (8).
3. Pull cylinder head and piston rod assembly (3)

out of cylinder (4).
a Prepare a container to receive oil which
flows out when the piston rod assembly is
pulled out of the cylinder.
2 HD465-7E0, HD605-7E0
6. Disassembly of piston assembly Assembly

1) Remove wear ring (9) from piston (10). a Apply engine oil to the sliding surfaces of each
2) Remove piston ring (11) from piston (10). part. When assembling, take care not damage
the packing, dust seal, and O-ring.
1. Assembly of cylinder head assembly

1) Using tool U4, press fit bushing (15) to cyl-
inder head (16).
a When press fitting the bushing, take
extreme care not to deform it.
2) Install rod packing (14).
a Install the rod packing as shown in
the following figure.
3) Install backup ring (18) and O-ring (17) in
order.
a Do not install the backup ring forcibly.
7. Disassembly of cylinder head assembly Warm it in water at 50 – 60°C before
1) Remove snap ring (12) and dust seal (13). installing it.
2) Remove rod packing (14). 4) Using tool U5, install dust seal (13) to cyl-
3) Remove bushing (15) from cylinder head inder head (16), and then install snap ring
(16). (12).
4) Remove O-ring (17) and backup ring (18).
2. Assembly of piston assembly

1) Using tool U6, expand piston ring (11).
a Set the piston ring to the tool and
rotate the handle 8 – 10 turns to
expand the piston ring.
2) Remove the piston ring from the tool and
install it to piston (10).
HD465-7E0, HD605-7E0 3
3) Set tool U7. Using tool U8, shrink the pis- 3) Remove piston rod assembly (3) from tool
ton ring. U1.
4) Install wear ring (9). 4. Set the cylinder to tool U1.
5. Install cylinder head and piston rod assembly

(3) to cylinder (4).
3. Assembly of piston rod assembly

1) Install cylinder head assembly (7) and pis-
ton assembly (6) to piston rod (8).
6. Using tool U2, tighten cylinder head assembly
(2).
3 Cylinder head nut:
637.5 ± 63.7 Nm {65 ± 6.5 kgm}
2) Using tool U3, tighten nut (5).

2 Nut: Adhesive (LOCTITE No. 262)
3 Nut:
1,078.8 ± 107.9 Nm {110 ± 11.0 kgm}
a Width across flats of nut: 50 mm
4 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5

© 2007 KOMATSU
All Rights Reserved
6 HD465-7E0, HD605-7E0
SEN02488-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Brake system
Removal and installation of front brake caliper pads ...................................................................................... 2
Removal and installation of front brake calipers assembly ............................................................................. 3
Disassembly and assembly of front brake calipers assembly......................................................................... 4
Removal and installation of final drive and rear brake assembly .................................................................... 6
Removal and installation of final drive, rear brake, and parking brake assembly ........................................... 9
Disassembly and assembly of final drive, rear brake, and parking brake assembly..................................... 10
HD465-7E0, HD605-7E0 1
Removal and installation of front Installation

brake caliper pads 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the front wheel assembly. For details, [*1]
see Removal and installation of front wheel a Push in the torque pin and fix it with the bolt
assembly. securely.
a Adjust the clearance between the pin and disc
2. Pull out torque pin (1). [*1] to 1.5 – 3 mm.
3 Pin fixing bolt:
a Pin fixing bolt (2) and pull out pin (1) to a
degree that you can remove the pads. 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
a For precautions for installing the pin fixing bolt,
see "Disassembly, assembly of front brake cal-
ipers assembly".
a Bleed air from the front brake circuit. For
details, see Testing and adjusting, "Bleeding
air from brake circuit".
3. Remove pads (3).

1) Install a vinyl hose to bleeder screw (4) so
that the brake oil will be drained.
2) Loosen the bleeder screw and return pis-
tons (5) with a bar to the bottoms of the
cylinders.
2 HD465-7E0, HD605-7E0
Removal and installation of front Installation

brake calipers assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the front wheel assembly. For details, [*1]
see "Removal and installation of front wheel
3 Mounting bolt:
assembly".
785 – 980 Nm {80.1 – 100 kgm}
2. Disconnect hose (1).
a Bleed air from the front brake circuit. For
3. Sling the calipers assembly temporarily and details, see Testing and adjusting, "Bleeding
remove bolts (2). [*1] air from brake circuit".
4. Remove calipers assembly (3).

a Sling the calipers assembly, adjusting it
with a lever block, etc.
4 Calipers assembly: 75 kg
HD465-7E0, HD605-7E0 3
Disassembly and assembly of Assembly

front brake calipers assembly 1
Disassembly
1. Pin fixing bolts (1) and (2) and remove torque
pins (3), (4), and (5) and pads (6).
2. Remove plate (7), plug (8), backup ring (9),

and seal (10).
3. Remove dust seal (11) and piston (12).
4. Remove seal (13) and backup ring (14).

a Disassemble the other pistons similarly.
1. Fit backup ring (14), seal (13), and dust seal

(11) to the grooves of torque plate (15).
2. Install piston (12).

a Fit the dust seal lip to the groove of the
piston.
3. Install seal (10), backup ring (9), plug (8), and

plate (7).
4. Install pads (6) and torque pins (5), (4), and (3)
and tighten pin fixing bolts (2) and (1).
3 Bolt: 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
4 HD465-7E0, HD605-7E0
a Unlike a usual bolt, each of the above

bolts has pointed end (part (a)). The
pointed end bites in the surface of torque
pin (5) (deforms the pin plastically) (Bitten
part: (b), Trace of biting: (c)) to fix the pin.
(The bolt must be tightened further after
resistance is felt.)
Accordingly, if the bolt is not tightened to
the specified torque, it cannot bite in and
fix the pin sufficiently.
a Move the pin in the axial direction, tighten-
ing the pin fixing bolts, check that the bolts
are fitted in the grooves of the torque pin.
a Be sure to install torque pin (4), (5) which

is shorter than torque pin (5) to the plate
side.
a Assemble the other pistons similarly.
5. Install the front brake calipers assembly. For

details, see "Removal and installation of front
brake calipers".
a Install the front brake calipers assembly
so that clearance (d) between disc plate
(16) and torque pin (3) will be 1.5 to 3.0
mm.
HD465-7E0, HD605-7E0 5
Removal and installation of final a Fix outer gear (5) and wheel hub (6) at fol-
lowing points (a), (b), (c) and (d) (4 points
drive and rear brake assembly 1 in total).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1610 Spacer t 4 N Q
J 1 01010-61620 Bolt t 4
01643-31645 Washer t 4
Removal
1. Remove the dump body assembly. For details, 6. Remove retainer (7) and shim (8). [*1]
see "Removal and installation of dump body a Before removing the retainer completely,
assembly". pass a guide bolt through the retainer, and
then pull out the retainer and ring gear
2. Remove the (outer and inner) rear wheel assembly together slowly and sling them.
assemblies on the side of the final drive and a Check the thickness and quantity of the
rear brake assembly to be removed. For shims.
details, see "Removal and installation of rear
wheel assembly".
3. Remove the final drive carrier assembly. For

details, see "Removal and installation of final
drive carrier assembly".
4. Release the parking brake. For details, see

Testing and adjusting, "Method of releasing
parking brake in an emergency".
5. Using tool J1, fix outer gear (5) and wheel hub
(6).
a Be sure to install tool J1 to protect the
floating seal before removing the retainer. 7. Remove ring gear assembly (9).
4 Ring gear assembly: 100 kg
6 HD465-7E0, HD605-7E0
8. When disassembling the ring gear assembly, 11. Remove 2 mounting bolts (18) of oil tank (17)
remove bolt (10) and take the assembly apart and 2 nuts of the stud bolts and pull out oil tank
into holder (11), inner hub (12), and ring gear (17) in the axial direction.
(13).
12. Remove 29 bolts (19) and pull out final drive

9. Sling final drive and rear brake assembly (14) and rear brake assembly (14) sideway to
temporarily. remove it.
4 Final drive and rear brake assembly:
800 kg
10. Remove clamp (16) of tube (15).
a Since bearing (20) comes off, take care

not to drop it.
a For disassembly and assembly, see Dis-

assembly and assembly of final drive,
"Rear brake, and parking brake assem-
bly".
HD465-7E0, HD605-7E0 7
Installation
removal.
k After installing, be sure to remove tool J1
and parking brake releasing bolt.
[*1]
q Adjusting preload on bearing
1) Install retainer (7) without inserting any
shim and tighten 3 mounting bolts to the
following torque.
a Rotating the hub 20 – 30 turns, tight-
en the bolts evenly to the specified
torque.
181 – 191 Nm {18.5 – 19.4 kgm}
[Target: 186 Nm {18.9 kgm}
2) Measure distance a between the end of
tube (17) and end of retainer (7) with
depth micrometer [2].
a Measure at 2 places and obtain the
average.
3) Remove retainer (7) and measure its thick-
ness (b).
a Measure at 2 places and obtain the
average.
4) Calculate shim thickness (c) by the follow-
ing expression.
(c) (mm) = (a) – (b) + 0.3
5) Install the shim of the calculated thickness
and retainer (7) with the all mounting bolts
(6 bolts).
a Rotating the hub 20 – 30 turns, tighten
the bolts evenly to the specified
torque.
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kg}
6) Rotate the wheel hub again and check
that it revolves normally.
8 HD465-7E0, HD605-7E0
Removal and installation of final

drive, rear brake, and parking
brake assembly 1
Removal
1. Perform Steps 1 – 7 of "Removal and installa-
tion of final drive and rear brake assembly".
a If the final drive, rear brake, and parking
brake assembly does not need to be dis-
assembled after removed, the parking
brake does not need to be released.
2. Disconnect hoses (1) and (2) and remove

pipes (3) and (4).
a Since bearing (20) comes off, take care
not to drop it.
3. Sling final drive, rear brake, and parking brake

assembly (5) temporarily.
4. Remove 30 nuts (6) and pull out final drive, Installation

rear brake, and parking brake assembly (5) q Carry out installation in the reverse order to
sideway to remove it. [*1] removal.
4 Final drive, rear brake, and parking
brake assembly: 2,150 kg [*1]
3 Mounting nut of final drive, rear brake, and
parking brake assembly:
490 – 608 Nm {50 – 62 kgm}
q Adjusting preload on bearing

See "Removal, installation of final drive and
rear brake assembly".
HD465-7E0, HD605-7E0 9
Disassembly and assembly of 3. Parking brake assembly

final drive, rear brake, and parking 1) Check that the parking brake is released.
(See Testing and adjusting, "Method of
brake assembly 1 releasing parking brake in an emer-
gency".)
Special tools 2) Remove parking brake assembly (1).
a Make match marks on parking brake
New/Remodel
assembly (1) and outer gear (5) for
Necessity
Sym-
Part No. Part name reference for installation.
Sketch
bol
Q'ty
792T-422-1610 Spacer t 4 N Q
1 01010-61620 Bolt t 4
01643-31645 Washer t 4
2 795-102-2102 Spring washer t 1
J
792-520-2110 Installer t 1
3
792-520-1600 Push tool t 1
791-585-1510 Installer t 1
4
792-530-1700 Push tool t 1
q For the sketch of tool J1, see "Sketch of spe-

cial tool". 4. Disassembly of parking brake assembly
k Since the installing load on the internal
spring is large, disassemble the
Disassembly assembly carefully according to the
k Remove the internal parts (piston, damper, following procedure.
disc, plate, floating seal, etc.) carefully so 1) Gradually loosen and remove parking
that they will not be damaged by impacts, brake releasing bolts (A) (10 pieces).
fall, etc. a Loosen all releasing bolts (A) evenly
so that the internal brake piston will
1. Place the final drive, rear brake, and parking not slant.
brake assembly with the parking brake side up. Reference: Total installing load on spring:
k Using blocks, etc., place the assembly Approx. 199 kN {20.3 ton}
stably.
2. Remove tool J1 which is fixing outer gear (5)

and wheel hub (6).
10 HD465-7E0, HD605-7E0
2) Turn over the parking brake assembly. 6) Remove seal rings (8) and (9) from cylin-
3) Gradually and evenly loosen and remove der (7).
13 cylinder mounting bolts (4).
7) Remove 30 springs (10) from cylinder (2).

4) Remove cylinder (7). a There are 22 double springs and 8
a Make match marks on cylinder (7) single springs.
and piston assembly (3) for reference a Make distinction marks at locations of
for installation. the single springs (8 places) with
paint for reference for installation.
5) Remove piston assembly (3).

a Make match marks on piston assem-
bly (3) and cylinder (2) for reference
for installation.
HD465-7E0, HD605-7E0 11
8) Turn over the piston assembly disassem- 11) Remove seal rings (17) and (18) from
bled in Step 5). brake piston (16).
9) Using tool J2, compress the springs and
remove pin (11), washer (12), spring (13),
and guide (14).
5. Dampers, discs, plates, and spacer

1) Remove plates (19).
2) Remove damper (20), 12 discs (21), 11

10) Remove parking brake piston (15). plates (22), and damper (23).
a Make match marks on parking brake
piston (15) and brake piston (16) for
reference for installation.
12 HD465-7E0, HD605-7E0
3) Install bolts [3] to the sling taps and 7. Inner gear

remove spacer (24). 1) Remove inner gear (27).
6. Outer gear 2) Remove floating seal (28) on the outside

1) Remove outer gear (5). of the inner gear, retainer (29), and float-
a Take care not to drop the floating seal ing seal (30) on the inside of the inner
from the bottom. gear.
2) Remove oil seal (25) and floating seal (26) 8. Wheel hub assembly
from outer gear (5). 1) Remove retainer and floating seal assem-
bly (31).
a Retainer and floating seal assembly
(31) is free when the inner gear (in
the previous section) is removed.
HD465-7E0, HD605-7E0 13
2) Remove floating seal (33) from retainer

(32).
3) Remove bearing (34).
4) Remove outer races (35) and (36).
14 HD465-7E0, HD605-7E0
Assembly
a Clean the all parts and check them for dirt or
damage.
a Coat the sliding surfaces with engine oil before
installing.
a Remove the white powder from the O-ring sur-
face of the floating seal with engine oil, etc.
k Even a slight flaw of the floating seal made
by an impact, fall, etc. can cause oil leak-
age. Accordingly, install the floating seal
carefully.

1) Install outer races (35) and (36).
4) Set retainer and floating seal assembly
(31) to the center.
a Set the assembly with the floating
seal side up.
2) Install bearing (34).
2. Inner gear
1) Using tool J3, install floating seal (30) to
the inside of inner gear (27).
3) Using tool J3, install floating seal (33) to

retainer (32).
a Thinly apply grease (G2-LI) to the top
of the floating seal.
HD465-7E0, HD605-7E0 15
2) Install retainer (29) to inner gear (27). 3. Outer gear

3) Using tool J4, install floating seal (28). 1) Using tool J4, install floating seal (26).
a Thinly apply grease (G2-LI) to the top
of the floating seal.
a After installing, measure distance (b)

between the end of outer gear (5) and
a After installing, measure distance (a) end of seal (26) at 4 points on the
between the end of retainer (29) and periphery. Check that the difference
end of seal (28) at 4 points on the between the values at the 4 points
periphery. Check that the difference does not exceed 1 mm.
between the values at the 4 points
does not exceed 1 mm.
2) Install oil seal (25).

a Apply grease to part (P) shown below.
4) Install inner gear (27). 2 Part (P): Grease (G2-LI)
a When installing the inner gear, match
it to the retainer and floating seal
assembly installed in Step 1-4).
a Take care not to damage the floating
seal.
3 Inner gear mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
16 HD465-7E0, HD605-7E0
3) Install outer gear (5). 3) Install discs (21) and plates (22) alter-
a Take care not to drop the floating seal nately in order.
from the bottom. a Install the 12 discs and 11 plates.
a Take care that the oil seal at the bot- 4) Install damper (20).
tom will not be rolled up.
a Install damper (20) with seat (b) (pro-

4. Dampers, discs, plates, and spacer jected part: 4.5 mm thick) up.
1) Install bolts [3] to the sling taps, and then k If the damper is installed reversely,
install spacer (24). the disc will be worn abnormally.
Accordingly, be sure to install it in
the correct direction.
a Install spacer (24) with the chamfered

side down.
2) Install damper (23). 5) Install plates (19).
a Install damper (23) with seat (a) (pro-
jected part: 1 mm thick) down.
k If the damper is installed reversely,
the disc will be worn abnormally.
Accordingly, be sure to install it in
the correct direction.
HD465-7E0, HD605-7E0 17
5. Assembly of parking brake assembly 3) Pass guide (14) through spring (13) and
k Since the installing load on the internal install them to the parking brake piston.
spring is large, assemble the assembly 4) Using tool J2, compress spring (13) and
carefully according to the following install washer (12) from the underside of
procedure. the brake piston. Pass pin (11) through
1) Install seal rings (17) and (18) to brake guide (14) to fix the guide.
piston (16).
Grease (G2-LI)
2) Install parking brake piston (15) to brake

piston (16).
a Match the match marks made when
the piston was removed.
18 HD465-7E0, HD605-7E0
5) Install 30 springs (10) to cylinder (2). a When installing the piston assembly,
a For the locations of the 8 single match it to dowel pin (C).
springs, see the distinction marks
made when they were removed.
8) Install guide bolt [2] and cylinder (7).

6) Install seal rings (8) and (9) to cylinder (7). the cylinder was removed.
2 Periphery of seal ring: a Match the faucet joint portion of cylin-
Grease (G2-LI) der (7) to that of cylinder (2) by hitting
cylinder (7) evenly with a plastic ham-
mer, etc.
7) Install piston assembly (3) to cylinder (2).

the piston assembly was removed. 9) Tighten 13 cylinder mounting bolts (4)
gradually and evenly to the specified
torque.
3 Mounting bolt:
153 – 190 Nm {15.6 – 19.3 kgm}
HD465-7E0, HD605-7E0 19
10) Apply hydraulic pressure to parking brake 7. Using tool J1, fix outer gear (5) and wheel hub
releasing port (P) (20 × 1.5) and check (6).
that the piston is pulled up and the parking
brake works.
q Parking brake releasing pressure:
8.7 MPa {85 kg/cm²}
a Fix outer gear (5) and wheel hub (6) at fol-

lowing points (a), (b), (c), and (d) (4 places
in total).
11) Tighten parking brake releasing bolts (A)

(10 pieces) gradually and evenly.
6. Install parking brake assembly (1) to outer gear

(5).
a Match the match marks made when the
parking brake assembly was removed.
20 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 21

© 2007 KOMATSU
All Rights Reserved
22 HD465-7E0, HD605-7E0
SEN02489-02
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Undercarriage and frame
Removal and installation of front wheel assembly .......................................................................................... 2
Removal and installation of rear wheel assembly ........................................................................................... 4
Removal and installation of front suspension cylinder assembly .................................................................... 6
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring) ...................... 8
Removal and installation of rear suspension cylinder assembly....................................................................11
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) ..................... 12
HD465-7E0, HD605-7E0 1
Removal and installation of front 6. Move the lift truck slowly in reverse to remove
wheel assembly (3).
wheel assembly 1 4 Wheel assembly: 1,200 kg
k The removed wheel assembly should be
Removal
k
placed flat on its side in a safe place.
When resting it against something, put
chocks under it to prevent it from falling
down.
1. Set a hydraulic jack [1] (50 t) under arm (1) and
a Take care not to break the air valves.
raise the front wheel assembly (3).
Reference: Procedure for jacking up either front

2. Support the frame on a stand [2], etc.
wheel
q The figure shows the left side.
1) Set hydraulic jack [1] (50 t) to holder (4) under
the king pin.
q Put steel plate [2] etc. between holder (4)
and jack [1] to disperse the surface pres-
sure.
Caution: q Set steel plate [2] so that
it will not contact bolt (5).
q Do not set the hydraulic
jack to A-frame (6). If it is
set so, the A-frame will be
deformed or damaged by
the load.
3. Insert the fork of a lift truck under wheel 2) Set stand [3] under frame (7) to stabilize the
assembly. machine.
4. Secure wheel assembly with wires, chain block,

etc.
5. Remove hub nuts (2). [*1]
2 HD465-7E0, HD605-7E0
Installation
removal.
[*1]
a Tighten the hub nuts evenly in the diagonal
order.
a Tighten the hub nuts permanently after lower-
ing the truck body.
3 Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
a After installing the wheel assembly, drive the
truck about 5 – 6 km, then check that the hub
nuts are tightened to the specified torque.
3) While checking stability, jack up carefully to
raise the wheel.
HD465-7E0, HD605-7E0 3
Removal and installation of rear

wheel assembly 1
Removal
1. Set a hydraulic jack [1] (50 t) under either rear

axle (6) and raise the rear wheel assembly.
7. Similarly to the outside wheel, secure wheel

assembly with wires, chain block, etc.
8. Remove inner hub nuts (4). [*2]
2. Loosen the locknut of the air valve and remove

lock plate (1).
3. Insert the fork of a lift truck under wheel

assembly.
4. Secure wheel assembly with wires, chain block,

etc.
5. Remove outer hub nuts (2). [*1] 9. Move the lift truck slowly in reverse to remove
wheel assembly (5).
4 Wheel assembly: 1,200 kg
down.
6. Move the lift truck slowly in reverse to remove

wheel assembly (3).
4 Wheel assembly: 1,200 kg
down.
4 HD465-7E0, HD605-7E0
Reference: Procedure for jacking up either rear Installation

wheel q Carry out installation in the reverse order to
q The figure shows the left side. (Condition after removal.
the wheel is removed is shown.)
1) Seat the body. [*1], [*2]
2) Set hydraulic jack [1] (50 t) to rear axle (3). a Tighten the hub nuts evenly in the diagonal
q Put steel plate [2] etc. rear axle (3) and order.
jack [1] to disperse the surface pressure. a Tighten the hub nuts permanently after lower-
3) Set stand [3] under the frame to stabilize the ing the truck body.
machine. 3 Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
a After installing the wheel assembly, drive the
truck about 5 – 6 km, then check that the hub
nuts are tightened to the specified torque.
4) While checking stability, jack up carefully to

raise the wheel.
HD465-7E0, HD605-7E0 5
Removal and installation of front 9. Remove 4 bolts (8).

1) Revolve the knuckle arm toward the truck
suspension cylinder assembly 1 body about 40 degrees and remove the
bolt marked with q.
Removal
2) Return the knuckle arm to its original posi-
1. Remove the front wheel assembly. For details,
tion and jack up the king pin and remove
the bolts marked with .
assembly".
2. Remove the front brake calipers assembly.

For details, see "Removal and installation of
front brake calipers assembly".
3. Remove the wheel hub assembly. For details,

hub assembly".
4. Release nitrogen gas. For details, see Testing

and adjusting, "Testing and adjusting front sus-
pension cylinder".
5. Disconnect hose (1). 10. Using a forklift, etc., sling the front suspension
cylinder assembly and pull out pin (9) on the
rod side.
11. Disconnect and remove front suspension cylin-

der assembly (10) from the knuckle arm.
4 Front suspension cylinder assembly:
500 kg
6. Disconnect tubes (2) and (3).
7. Pull out pin (4) and disconnect tie rod (5).
8. Pull out pin (6) and remove steering cylinder

(7). [*1]
6 HD465-7E0, HD605-7E0
Installation
removal.
[*1]
k Never align the pin with the pin hole by
starting the engine and operating the steer-
ing wheel. It is very dangerous.
When aligning the pin and pin hole, discon-
nect the hoses on the head side and bottom
side of the steering cylinder so that you can
adjust the length of the steering cylinder
rod. Use a lever block or a bar to align
them.
k Before operating the steering system after
finishing installation, be sure to refill the
front suspension cylinder with nitrogen gas
and adjust it. For details, see Testing and
adjusting, "Testing and adjusting front sus-
pension cylinder".
HD465-7E0, HD605-7E0 7
Disassembly and assembly of 2. Remove feed valve (1) and valve (2).
front suspension cylinder
3. Removal of cylinder rod assembly.
assembly 1) Remove flange mounting bolts (3) and air
(Cylinder with buffer ring) 1 bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
Special tools retainer (7), and flange (8) together.
New/Remodel
4. Disassembly of flange
Necessity
Sym- 1) Remove plate (6), retainer (7), and flange
Part No. Part name
Sketch
bol
(8) from rod assembly (5).
Q'ty
2) Remove dust seal (9) and bushing (10)
792-103-4102 Push tool t 1 from retainer (7).
792-625-1300 Push tool t 1 3) Remove U-packing (11), buffer ring (14)
1 and bushing (12) from flange (8).
790-101-5421 Grip t 1
Q 01010-81240 Bolt t 1 5. Remove wear ring (13) from cylinder rod (5).
792-610-1000 Suspension tool t 1
2 792-610-1100 • Pump assembly 1
792-610-1200 • Charging tool 1
Disassembly
q Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
8 HD465-7E0, HD605-7E0
Assembly k Buffer ring (14) is made of 2 parts. When

(See the figure for disassembly, too.) installing it, set the round corner of part [2]
(Black) inside of part [1] (Blue).
1. Installation of wear ring q The side indicated by the arrow is the
Install wear ring (13) to cylinder rod (5). pressure side.
2 Outside of wear ring:
Engine oil (EO10-CD)
2. Assembly of flange
1) Using tool Q1, press fit bushing (12) to
flange (8) and install U-packing (11) and
buffer ring (14).
2 Inside of bushing:
Engine oil (EO10-CD)
a When installing the U-packing, check
that there are 4 projections on the top
of the inside lip.
2) Press fit bushing (10) to retainer (7) and

install dust seal (9).
a When press fitting the bushing, take
care not to deform it.
2 Periphery of seal: Adhesive (LT-2)
3. Assembly of cylinder rod assembly

1) Install flange (8), retainer (7), and plate (6)
to the cylinder rod.
2 Mating faces of flange and retainer:
a Apply the gasket sealant evenly to
a Apply rust-preventive oil to part (A) hatched part (B) and apply it thinly to
indicated with 2-dot chain lines on the U-packing (C) so that it will not be
periphery of the U-packing (NISSEKI projected.
P1300 or equivalent).
2) Using a block, erect the cylinder.

a Fill the cylinder with engine oil.
5 Cylinder: Approx.
16.5 l (EO10-CD)
HD465-7E0, HD605-7E0 9
3) Sling cylinder rod assembly (5) and install

it to the cylinder.
a If the rod assembly is inserted too
deep, the oil spouts out. Stop it to a
position where the oil does not spout
out.
a After installing the front suspension
assembly to the truck body, adjust the
oi l and gas , using tool Q2. For
details, see "Testing and adjusting
front suspension cylinder".
4) Install flange (8), retainer (7), and plate (6)
to the cylinder with bolts (3).
3 Mounting bolt:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
5) Install air bleeding valve (4).
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install valve (2) and feed valve (1).

3 Oil level valve and air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
a The dust cover consists of 2 pieces.
Reduce the clearance between them to
0.5 mm or less.
10 HD465-7E0, HD605-7E0
Removal and installation of rear Installation

suspension cylinder assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Stop the machine on a ground and lock the [*1], [*2]
k When aligning the pin holes, never insert
tires with chocks.
k Disconnect the cable from the negative (–) your fingers in them.
terminal of the battery. a Refill the rear suspension cylinder with nitro-
gen gas and adjust it. For details, see Testing
1. Release nitrogen gas. For details, see Testing and adjusting, "Testing and adjusting rear sus-
and adjusting, "Testing and adjusting rear suspension cylinder".
pension cylinder".
2. Remove protector (1).
3. Using a forklift, etc., sling the rear suspension

cylinder assembly and pull out pin (2) on the
bottom side.
4. Pull out pin (3) on the rod side and remove rear
suspension cylinder assembly (4).
4 Rear suspension cylinder assembly:
180 kg
HD465-7E0, HD605-7E0 11

rear suspension cylinder
assembly
(Cylinder with buffer ring) 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-103-4102 Push tool t 1
792-625-1300 Push tool t 1
1 5. Flange and retainer
790-101-5421 Grip t 1
1) Remove retainer (6) and flange (8) from
Q 01010-81240 Bolt t 1
cylinder rod assembly (7).
792-610-1000 Suspension tool t 1 2) Remove U-packing (10), buffer ring (17),
2 792-610-1100 • Pump assembly 1 backup ring and O-ring (11) from flange
792-610-1200 • Charging tool 1 (8).
3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
Disassembly retainer (6).
1. Guard
Sling the cylinder assembly and loosen clamp
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.
3. Feed valve and valve

Remove cover (3), feed valve (4), and valve
(5).
6. Wear ring
Remove wear ring (15) from rod (16).
4. Cylinder rod assembly

1) Erect the cylinder assembly upside down.
2) Remove the mounting bolt of retainer (6).
3) Slowly sling and remove cylinder rod
assembly (7), retainer (6), and flange (8)
as 1 unit from cylinder (9) with a crane.
12 HD465-7E0, HD605-7E0
Assembly 3. Retainer
1. Wear ring 1) Using tool Q1, install bushing (14) to
Install wear ring (15) to rod (16). retainer (6).
2) Install seal (13) to retainer (6).
2 Periphery of seal: Adhesive (LT-2)
2. Flange
1) Using tool Q1, install bushing (12) to
flange (8). 4. Cylinder rod assembly
2) Install U-packing (10) and buffer ring (17) 1) Using a block, erect cylinder (9).
to flange (8). 2) Sling cylinder rod assembly (7) and install
a Apply rust-preventive oil to part (A) it to cylinder (9).
indicated with 2-dot chain lines on the 3) Install flange (8) and retainer (6) to cylin-
periphery of the U-packing (NISSEKI der rod assembly (7).
P1300 or equivalent). 2 Mating faces of flange and retainer:
k Buffer ring (17) is made of 2 parts. Gasket sealant (LG-6)

When installing it, set the round a Apply the gasket sealant evenly to
corner of part [2] (Black) inside of hatched part (B) and apply it thinly to
part [1] (Blue). U-packing (C) so that it will not be
3) Install backup ring and O-ring (11) to projected.
flange (8).
HD465-7E0, HD605-7E0 13
4) Install retainer (6) and flange (8) together

to cylinder (9) with the mounting bolts.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
5. Feed valve and valve

1) Set the cylinder assembly upside down.
(Set the rod down.)
2) Sling the cylinder so that dimension (D) on
the rod side will be as follows.
When buffer ring is not installed:
140 ± 3 mm
When buffer ring is installed: 124 ± 3 mm
3) Supply oil through the oil level port with

the oil level pump and spout oil from the
air intake port until bubbles do not come
out any more.
4) After supplying oil, install level (5) and
feed valve (4).
3 Air intake valve and oil level:
39.2 – 49.0 Nm {4 – 5 kgm}
5) Install cover (3).
6. Guard
1) Install guard (2) and secure it with clamp
(1).
3 Clamp:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
14 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 15

© 2009 KOMATSU
All Rights Reserved
16 HD465-7E0, HD605-7E0
SEN02490-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Hydraulic system
Disassembly and assembly of hoist cylinder assembly .................................................................................. 2
HD465-7E0, HD605-7E0 1
Disassembly and assembly of 1. Set the cylinder assembly to tool U1.

hoist cylinder assembly 1 2. Using tool U2, remove cylinder head assembly
Special tools (1) from cylinde (2).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-502-1003 Repair stand t 1
1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench t 1
3 790-720-1000 Expander t 1
Ring
4 796-720-1680 t 1
(for cylinder )
Clamp
5 07281-01580 t 1
(for cylinder ) 3. Remove cylinder and rod assembly (3) from
792-201-7310 Push tool t 1 cylinder (2).
790-101-5421 Grip t 1
01010-81240 Bolt t 1
U 6 790-201-1702 Push tool KIT t 1
790-201-1851 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
792-201-7410 Plate t 1
790-101-5021 Grip t 1
01010-80816 Bolt t 1
7 790-201-1500 Push tool KIT t 1
790-201-1660 • Push tool 1
790-201-5021 • Grip 1 4. Remove piston nut (4) and lift down rod (6)
01010-50816 • Bolt 1 from cylinder (5).
5. Pull cylinder assembly (1) out of rod (6).

Disassembly
q When disassembling, take care not to damage
the rod packing, dust seal, piston ring, wear
ring, etc.
2 HD465-7E0, HD605-7E0
6. Disassembly of cylinder head assembly Assembly

1) Remove snap ring (7) and dust seal (8)
from cylinder head assembly (1). a Check each part for dirt, flaw, etc. and apply
2) Remove rod packing (9) and bushing (10). engine oil to the sliding surfaces before
3) Remove backup ring (11) and O-ring (12). assembling.
1. Using tool U6, press fit bushing (21) to cylinder

(5).
7. Disassembly of piston assembly and cylin-

der
1) Remove wear ring (13).
2) Remove snap ring (14) and pull out piston 2. Install rod packing (20) to cylinder (5).
assembly (15). a Install the rod packing as shown in the fol-
3) Remove piston ring (16) and wear ring (17) lowing figure.
from piston assembly (15).
4) Remove snap ring (18) from cylinder (5), 3. Using too U7, install dust seal (19).
and then remove dust seal (19).
5) Remove rod packing (20) and bushing (21).
4. Install snap ring (18).
HD465-7E0, HD605-7E0 3
5. Assembly of piston assembly 7. Install wear ring (13) to cylinder (5).

1) Using tool U3, expand piston ring (16) and
install it to piston (15).
a Set the piston ring to tool U3 and
rotate the handle 8 – 10 turns to
expand the piston ring.
2) Set tool U4. Using tool U5, shrink piston
ring (16).
8. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (10).
3) Install wear ring (17).
9. Install rod packing (9) to cylinder head (1).

a Install the rod packing as shown in the fol-
lowing figure.
6. Install piston assembly (15) to cylinder (5),

and then install snap ring (14).
4 HD465-7E0, HD605-7E0
10. Using tool U7, install dust seal (8). 15. Install cylinder and rod assembly (3) to cyl-
inder (2).
11. Install snap ring (7), O-ring (12), and backup

ring (11). 16. Using tool U2, tighten cylinder head assembly
(1).
3 Cylinder head assembly:
1,569.1 ± 156.9 Nm {160 ± 16 kgm}
12. Install head assembly (1) to rod (6).
13. Sling rod (6) and install it to cylinder (5).

a Align the bolt holes of the piston assembly
and rod.
14. Tighten piston mounting nut (4).

a Degrease the fitting parts of the bolt and
nut sufficiently.
a Width across flats of bolt: 24 mm
2 Threads of piston rod:
Adhesive (Loctite No. 262)
3 Mounting nut:
274 ± 27.4 Nm {28 ± 2.8 kgm}
HD465-7E0, HD605-7E0 5

© 2007 KOMATSU
All Rights Reserved
6 HD465-7E0, HD605-7E0
SEN02491-02
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Body
Removal and installation of body assembly .................................................................................................... 2
HD465-7E0, HD605-7E0 1
Removal and installation of body 3. Disconnect body potentiometer linkage (3)

from the body side. [*2]
assembly 1
4. Remove right and left body hinge pins (4). [*3]
Special tools
a Check the thickness, quantity and posi-
tions of the inserted shims. [*4]
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
V 1 790-441-1320 Hook t 1 Q
Removal
k Raise the poke ejector and set it in parallel
with the body.
1. Using tool V1, sling the body assembly by 4 5. Lift off body assembly (5). [*5]
4 Body assembly
parts.
HD465-7E0: 10,730 kg
2. Remove hoist cylinder bottom pin (1). [*1]
HD605-7E0: 13,418 kg
a Fix hoist cylinder (2) with a lever block etc.
so that it will not fall down when pin (1) is
removed.
a Remove the pin on the opposite side simi-
larly.
Installation
removal.
[*1]
kWhen aligning the pin holes, never insert
your fingers in the pin holes.
3 Lock plate mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*2]
a Adjust the boom positioner sensor. For details,
see Testing and adjusting, "Adjusting boom
positioner sensor".
2 HD465-7E0, HD605-7E0
[*3] [*5]
kWhen aligning the pin holes, never insert q Adjusting body mount shim
your fingers in the pin holes. 1. Adjust the body mount shim.
a Insert the shims as checked when removed. 1) Insert 29 mm thick spacer [1] in the end of
3 Lock plate mounting bolt: body (5). (1 place each on right and left
245 – 309 Nm {25 – 31.5 kgm} sides)
2) Measure the clearance between each of
rubber pads (6) (A), (B) and (C) installed
[*4] on the right and left sides and rear frame
a After installing the body, check that difference top (7).
(Z) between the levels of the body assembly q Shim thickness = (X - 26) mm
and cab assembly is in the following range. 3) If there is any clearance, add shim (8) to
q Standard value of difference (Z): eliminate it.
with in 58 ± 12 mm q Standard shim thickness at (A), (B)
and (C): 3 mm
q Kinds of shim thickness:
1 mm, 3.2 mm
4) Remove spacer [1], lower the body, and
check that all of 6 rubber pads (A), (B) and
(C) are in contact with the rear frame top
(7).
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a If difference (Z) is out of the standard, adjust it

with spacers (6) of the right and left body hinge
pins.
q Kinds of spacer thickness: 1 mm, 6 mm
a Clearance (Y) must be 1 mm or less.
HD465-7E0, HD605-7E0 3
2. Adjust the front mount shim.

q After adjusting the bottom mount shim,
adjust the right and left front mount shims.
1) Lower the body and measure thickness
(Y) of rubber pad (9).
q Standard shim thickness: 7 mm
2) If the thickness is larger than the stan-
dard(rubber pads) or there is a clearance
between the body and rubber pad, add
shim (10) to adjust height (Y) to the stan-
dard(rubber pads).
q Standard height (Y): 50 mm
4 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5

© 2009 KOMATSU
All Rights Reserved
6 HD465-7E0, HD605-7E0
SEN02492-03
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Cab and its attachments
Disassembly and assembly of operator's seat assembly................................................................................ 2
Removal and installation of air conditioner unit assembly .............................................................................11
HD465-7E0, HD605-7E0 1
Disassembly and assembly of operator's seat assembly 1

a The procedure for disassembling and assembling the operator's seat assembly (air suspension (Isring
hausen)) is shown below.
A: Headrest E: Left-hand armrest

B: Seatback F: Suspension cover
C: Seat cushion G: Rails
D: Right-hand armrest
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of the 2 clips (2) of headrest stay (1) on
both sides.
2 HD465-7E0, HD605-7E0
2) Apply force b to part a of each clip (2) in 2. Seatback

the direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear
Release headrest stay (1) from part d of left of seatback (4).
the clip and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HD465-7E0, HD605-7E0 3
4) Apply force E to the right side of seatback 2) Push cushion stopper wire (9) down with
(4) in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and
right side up. remove it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion q The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward armrest (10) is shown below. (Disassemble
and slide seat cushion (8) to the front end. left-hand armrest (11) similarly.)
4 HD465-7E0, HD605-7E0
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment
a Use a flat-head screwdriver, etc. to washers (16) installed to each bolt
remove the cap. between the armrest and seatback.
2) Loosen armrest hinge mounting bolt (13). Take care not to lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of 1) Remove right-hand hinge cover (17).
right-hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
4) Turn right-hand armrest (10) up by 180

degrees.
a If the armrest is not turned, you can-
not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B)
HD465-7E0, HD605-7E0 5
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
6 HD465-7E0, HD605-7E0
2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part 1. Slide rails
of each rail. 1) Put height adjustment washers (31)
between slide rails (28) and suspension,
and then set slide rails (28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part 2) Set slide rails (28) to the front end and
of each rail, and then remove rails (28). install 1 lock washer (30) and 1 hexagon
socket head bolt (29) to each slide rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
3) Set slide rails (28) to the rear end and
install 1 lock washer (30) and 1 hexagon
socket head bolt (29) to each slide rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HD465-7E0, HD605-7E0 7
2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails

1) Set suspension cover (27) in position and (22), and then install cushion rear fixing
install 6 plastic suspension cover clips plate (21), and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension 3 Cushion rail mounting bolt:
cover clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings

(19).
2) Install 3 metallic suspension cover clips

(24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
8 HD465-7E0, HD605-7E0
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

q The procedure for assembling right-hand a Tighten the bolt so that the arm will
armrest (10) is shown below. (Assemble move smoothly.
left-hand armrest (11) similarly.) q Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set right-hand armrest
(10) in position. 4. Seat cushion
1) Slide in the seat cushion from the front of
the fitting position.
a If seat cushion (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly

and turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
HD465-7E0, HD605-7E0 9
5. Seatback 3) Connect 3 air hoses (5) to the rear left of

1) Insert the left side of seatback (4), and the seatback (4).
then lower and set the right side.
6. Headrest
1) Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6).

3 Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
10 HD465-7E0, HD605-7E0
Removal and installation of air 4. Disconnect hose (5).

conditioner unit assembly 1 5. Remove duct (6) – (8). [*2]
Removal
6. Remove covers (9) and (10).
lower the work equipment and touch per-
fectly to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal of the
battery beforehand.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmo-
7. Remove dashboard cover (11).
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 1,100 g
2. Remove floor mat.
3. Remove covers (1) – (4). 8. Disconnect air conditioner hose and tube (12)
– (15).
HD465-7E0, HD605-7E0 11
9. Disconnect connector (16), connector CG1 Installation

(17), and connector TCHET (18), connector
AC1 (19) and connector AS1(20). q Carry out installation in the reverse order to
removal.
[*1]
Charge the air conditioner circuit with refrigerant
(R134a air conditioner gas).
a Take care that dirt, dust, water, etc. will not
enter the air conditioner circuit.
a Before proceeding to the installation, check
that the O-ring is provided at the air conditioner
hose connection.
a Check the O-ring for scratches or degradation.
2 O-ring: ND-OIL8
q Quantity of refrigerant: 1,100 g
10. Removal air conditioner unit assembly. [*2]

Assembly procedure for air duct
1. Install vent duct (1) and foot duct (2) to the
dashboard bracket (Make up the sub-assem-
bly).
2. Couple the air duct sub-assembly with the air

conditioner unit.
a Be sure to check that faucet joint portion
(a) is assembled normally.
a If faucet joint portion (a) is not inserted
normally, the dashboard mounting portion
floats.
a If the dashboard is assembled while it is
floating, the air conditioner opening is
deformed.
1. Vent damper
2. Foot damper
3. Face damper
4. Air conditioner unit
Check that faucet joint portion: a
12 HD465-7E0, HD605-7E0
q Refilling with coolant

specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
HD465-7E0, HD605-7E0 13

© 2009 KOMATSU
All Rights Reserved
14 HD465-7E0, HD605-7E0
SEN02493-01
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 3
Removal and installation of retarder controller assembly ............................................................................... 4
HD465-7E0, HD605-7E0 1

engine controller assembly 1
Removal
k Stop the machine on a level ground, apply
the parking brake, and then lock the tires
with chocks.
1. Remove left engine side cover.

a Remove the cover only when it is in-
stalled.
4. Disconnect engine ground cables GS (7) and
2. Remove hose clamp mounting bolts (1) and
E80 (8).
(2).
5. Disconnect connectors J3P (9) and connector

3. Remove engine controller covers (3) – (5).
ENG (10) and connector J2P (11) engine con-
a Atmosphere sensor (6) is installed to the
troller.
engine controller or reverse of cover (3).
Disconnect it carefully.
6. Remove engine controller (12).
Installation
removal.
2 HD465-7E0, HD605-7E0

transmission controller
assembly 1
Removal
with chocks.
1. Remove seat rear cover.
2. Disconnect connectors (2) from transmission

controller (1).
q Connector, ATC1, ATC2, ATC3
3. Remove transmission controller (1).
Installation
removal.
HD465-7E0, HD605-7E0 3

retarder controller assembly 1
Removal
with chocks.
1. Remove seat rear cover.
2. Disconnect connectors (2) from retarder con-

troller (3).
q Connector, BRC1, BRC2, BRC3
3. Remove retarder controller (3).
Installation
removal.
4 HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 5

© 2007 KOMATSU
All Rights Reserved
6 HD465-7E0, HD605-7E0
SEN01105-03
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 2
Steering and hoist hydraulic circuit diagram ................................................................................................... 3
Brake hydraulic circuit diagram....................................................................................................................... 7
HD465-7E0, HD605-7E0 1
SEN01105-03 90 Diagrams and drawings
Power train hydraulic circuit diagram 1
2 HD465-7E0, HD605-7E0
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10612
HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10612 HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10612
HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10612
HD465-7E0, HD605-7E0 3
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD465-7E0 Serial No.: 10614 and up HD605-7E0 Serial No.: 10613 and up
HD465-7E0, HD605-7E0 5
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 7
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

ASR specification
HD465-7E0, (If equipped)
HD605-7E0
ASR specification (If equipped)
HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 9
HD465-7E0, HD605-7E0 11

© 2009 KOMATSU
All Rights Reserved
12 HD465-7E0, HD605-7E0
SEN01106-06
DUMP TRUCK
HD465-7E0
HD605-7E0

HD465-7E0 10001 – 10037
HD465-7E0 10101 and up
HD605-7E0 8001 – 8032
HD605-7E0 10101 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram inside cab (1/3) ....................................................................................................... 3
Electrical circuit diagram outside cab (1/3) ..................................................................................................... 9
Electrical circuit diagram outside cab (2/3) ....................................................................................................11
Electrical circuit diagram outside cab (3/3) ................................................................................................... 13
Electrical circuit diagram for VHMS .............................................................................................................. 15
Electrical circuit diagram for ASR (If equipped) ............................................................................................ 17
Air conditioner electrical circuit diagram ....................................................................................................... 19
Electrical circuit diagram for auto greasing (If equipped).............................................................................. 21
Connectors table and arrangement drawing ................................................................................................. 23
HD465-7E0, HD605-7E0 1
2 HD465-7E0, HD605-7E0
Electrical circuit diagram inside cab (1/3) Electrical circuit diagram inside cab (1/3) 1
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 3
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 5
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 7
Electrical circuit diagram outside cab (1/3) Electrical circuit diagram outside cab (1/3) 1
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 9
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 11
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 13
Electrical circuit diagram for VHMS Electrical circuit diagram for VHMS 1
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 15
Electrical circuit diagram for ASR (If equipped) Electrical circuit diagram for ASR (If equipped)
HD465-7E0, HD605-7E0
SEN01106-06
HD465-7E0, HD605-7E0 17
Air conditioner electrical circuit diagram Air conditioner electrical circuit diagram
HD465-7E0, HD605-7E0
HD465-7E0, HD605-7E0 19
Electrical circuit diagram for auto greasing (If equipped) 1
HD465-7E0, HD605-7E0 21
22 HD465-7E0, HD605-7E0
Connectors table and arrangement drawing
Connectors table and arrangement drawing HD465-7E0,605-7E0 HD465/605-7E0
ConnectorNo. Type of Number Location Address Type of Number ConnectorNo. Type of Number Location Address Type of Number
connector of pin ConnectorNo. Location Address connector of pin ConnectorNo. Location Address
connector of pin connector of pin
53 Terminal 1 Emergency steering relay B-8 CJE3 DT2B 8 Joint connector M-5 FOG M 6 Fog lamp switch (if equipped) W-1 PR07 Terminal 1 Ground B-4
54 Terminal 1 Emergency steering relay B-7 CJE4 DT2B 8 Joint connector J-9 FR01 DT2 2 Air cleaner clogging sensor C-7 PSOLR DT2 2 Parking brake solenoid M-5
55 Terminal 1 Emergency steering relay B-7 CJG DT2 6 Joint connector M-8 FUA1 Circuit breaker (30A) B-6 PSWR DT2 2 Parking brake switch M-4
56 Terminal 1 Emergency steering relay B-7 CJHL DT2B 8 Joint connector FUA2 Circuit breaker (30A) B-7 PWL_F 1 Power window motor (left) I-2
58 Terminal 1 Battery relay C-8 CJK DT2 6 Intermediate connector D-8 FUB1 Circuit breaker (80A) A-6 PWL_M 1 Power window motor (left) J-2
59 Terminal 1 Battery relay C-8 CJL DT2 6 Joint connector G-9 FUB2 Circuit breaker (80A) A-6 PWM M 6 Power mode switch Z-2
60 Terminal 1 Battery relay D-8 CJN DT2 6 Joint connector G-9 FUEL DT2 2 Fuel gauge sensor H-9 PWR_F 1 Power window motor (right) E-8
61 Terminal 1 Battery relay D-8 CJP DT2 6 Joint connector M-8 G DT2 3 G sensor AN-9 PWR_M 1 Power window motor (right) F-8
62 Terminal 1 Circuit breaker (80A) A-7 CJP1 DT2 6 Joint connector I-9 GDL DT2B 12 Intermediate connector R01 Relay 5 Engine start relay AF-4
63 Terminal 1 Circuit breaker (80A) A-7 CJP2 DT2 6 Joint connector J-9 GND Terminal 1 Ground C-3 R02 Relay 5 Transmission neutral relay AF-4
64 Terminal 1 Circuit breaker (80A) B-6 CJPR DT2 6 Joint connector E-8 GS Terminal 1 Ground AM-6 R03 Relay 5 Parking brake relay AF-3
65 Terminal 1 Circuit breaker (80A) A-6 CJR DT2 6 Joint connector L-9 H Terminal 1 Ribbon heater C-2 R04 Relay 5 Stop lamp relay AF-3
66 Terminal 1 Circuit breaker (30A) B-7 CJSL DT2 6 Joint connector I-9 H01 DT2 3 Steering pressure switch K-2 R05 Relay 6 Back lamp / buzzer relay AF-3
67 Terminal 1 Circuit breaker (30A) A-7 CJV DT2 6 Joint connector L-9 HAZ M 6 Hazard switch AB-4 R06 Relay 6 Fog lamp relay AF-4
68 Terminal 1 Circuit breaker (30A) B-7 CJY DT2 6 Joint connector M-7 HEPC DT2 2 Hoist EPC valve M-5 R08 Relay 5 Stop lamp relay AF-4
69 Terminal 1 Circuit breaker (30A) B-7 CK1_F M 6 Bulb breakage check switch X-2 HM12 DT2 3 Blow-by sensor AM-6 R11 Relay 5 Horn relay AF-3
70 Terminal 1 Emergency steering relay B-8 CM DT2C 8 Lighting switch, passing light switch, turn signal swtich R-1 HM2130 - 2 Junction connector R14 Relay 5 BCV relay AF-3
71 Terminal 1 Emergency steering relay B-8 CN1 DT 2 Injector #1 AJ-8 HM2140 - 2 Junction connector R16 Relay 6 Hazard relay 1 AF-4
72 Terminal 1 Emergency steering relay B-9 CN10 DT2 2 3rd Clutch ECMV AE-9 HM-21A - 2 Exhaust temperature sensor R17 Relay 5 Hazard relay 2 AF-4
73 Terminal 1 Emergency steering relay B-9 CN11 DT2 2 3rd Fill switch AE-9 HM-21B - 2 Exhaust temperature sensor R19 Relay 5 Parking brake safety relay AF-2
74 Terminal 1 Battery relay B-9 CN12 DT2 2 R Clutch ECMV AE-9 HM-22A - 2 Exhaust temperature sensor amp R21 Relay 6 Side lamp relay AF-2
75 Terminal 1 Battery relay B-9 CN13 DT2 2 R Fill switch AE-9 HM-22B - 2 Exhaust temperature sensor amp R22 Relay 5 Revolving relay AF-2
76 Terminal 1 Battery relay C-9 CN14 DT2 2 4th Clutch ECMV AE-9 HM-23A - 3 Exhaust temperature sensor amp R25 Relay 11 Power window relay AB-8
77 Terminal 1 Battery relay C-9 CN15 DT2 2 4th Fill switch AD-9 HM-23B - 3 Exhaust temperature sensor amp R29 Relay 5 Head lamp relay (Hi) (PASS) AF-4
81 Terminal 1 Fuse (120A) D-8 CN16 DT2 2 Torque converter lock-up solenoid AD-8 HM-50 - 3 Connector R30 Relay 5 Head lamp relay (Hi) AG-4
83 Terminal 1 Fuse (120A) D-8 CN17 DT2 2 Lo Clutch ECMV AD-8 HM-55 - 3 Protocol connector R31 Relay 5 Head lamp relay (Lo) AG-4
250 2 Resistor (male) Y-1 CN18 DT2 2 Lo Fill switch AC-8 HM-81 - 8 Intermediate connector (if equipped) R32 Relay 5 Dust indicator relay AF-2
1020 2 Resistor (male) Z-1 CN19 DT2 2 Hi Clutch ECMV AC-8 HM-CN1 - 20 VHMS & Payload meter controller R33 M 6 Parking brake manual switch
A1_M 1 Connector AH-2 CN2 DT 2 Injector #2 AJ-9 HM-CN2A - 18 VHMS & Payload meter controller R34 M 7 Power window switch (right) U-9
A1_F 1 Connector AG-1 CN20 DT2 2 Hi Fill switch AD-8 HM-CN2B - 12 VHMS & Payload meter controller R35 M 7 Power window switch (left) U-9
ABS M 6 ABS system switch AB-1 CN21 DT2 2 Torque converter intermediate oil pressure sensor AD-5 HM-CN3A - 18 VHMS & Payload meter controller R37 Relay 5 Auto preheat relay AF-2
ABS1 DRC_keyA 24 ABS controller CN22 DT2 2 Torque converter oil temperature sensor AE-5 HM-CN3B - 12 VHMS & Payload meter controller R40 Relay 6 Payload meter relay (if equipped) AG-4
ABS2 DRC_keyA 40 ABS controller CN23 DT2 2 Transmission oil temperature sensor AG-5 HM-CN4A - 14 VHMS & Payload meter controller R43 Relay 5 Payload meter external indicator lamp blue relay AG-4
ABS3 DRC_keyB 40 ABS controller AH-1 CN26 DT2 2 Main pressure switch AC-7 HM-CN4B - 10 VHMS & Payload meter controller R44 Relay 5 Payload meter external indicator lamp yellow relay AG-3
ABS6 4 Intermediate connector CN27 DT2 2 Main pressure ficed valve AC-6 HN 1 Horn switch Y-1 R45 Relay 5 Payload meter external indicator lamp red relay AG-2
ABS7 DT2C 12 Intermediate connector V-9 CN3 DT2 2 Input shaft speed sensor AG-9 HN1 DT2 2 Horn valve B-3 R46 Relay 5 Small lamp relay AF-2
ABS8 DT2B 12 Intermediate connector W-9 CN3 DT 2 Injector #3 AK-9 HN2 DT2 2 Horn valve B-3 R50 Relay 5 Emergency steering timer relay AG-2
ABS9 DT2A 12 Intermediate connector W-9 CN4 DT2 2 Intermediate shaft speed sensor AG-9 HN25 DT2 2 VHMS indicator RAD 9 Cassete stereo AM/FM radio Q-7
AC1 M 6 Intermediate connector O-5 CN4 DT 2 Injector #4 AL-9 HSL DT2 4 Hoist lever potentio meter RE1 2 Junction connector AE-2
ACC Terminal 1 Starting switch ACC terminal P-9 CN5 DT2 2 Output shaft speed sensor AH-7 HSOL DT2 2 Hoist selector valve M-5 RE3 2 Junction connector Z-2
ACCF DT2 3 ACC oil pressure (front) M-4 CN5 DT 2 Injector #5 AL-9 HTA DT-T 12 Intermediate connector M-6 RE4 2 Junction connector Y-1
ACCR DT2 3 ACC oil pressure (rear) L-3 CN6 DT2 2 1st Clutch ECMV AF-9 HTB DT-T 8 Intermediate connector M-6 RES DT2 2 Resistor
AISS M 6 AISS switch (if equipped) Q-8 CN6 DT 2 Injector #6 AM-9 INJ DT2 12 Intermediate connector AM-7 RESW DT2 3 Retarder switch
ARC M 3 ARSC set switch Q-2 CN7 DT2 2 1st Fill switch AF-9 J01 HD-55891 9 Intermediate connector AA-7 REVR DT2 2 Retarder valve
ARSC M 6 ARSC system switch AA-1 CN8 DT2 2 2nd Clutch ECMV AF-9 J02 DRC-16- 70 Intermediate connector AA-6 RL M 2 Room lamp F-9
70PAE
AS1 DT2 6 Accel sensor O-6 CN9 DT2 2 2nd Fill switch AE-9 RL2 2 Room lamp 2 H-9
DRC-16-
AS2 DT2 2 Accel sensor potentiometer O-6 CNS1 DT2D 12 Intermediate connector T-9 J03 70PBE 70 Intermediate connector AA-5 RLY Terminal 1 heater relay C-9
AS3 DT2 3 Pitch angle sensor AA-7 CNS2 DT2C 12 Intermediate connector T-9 DRC-16- RP DT2 8 Intermidiate connector B-4
J04 70 Intermediate connector AA-6
ASR M 6 ASR system switch AB-4 CNS3 DT2B 12 Intermediate connector T-9 70PBE RTL DT2 6 Retarder lever potentio meter R-2
ASR1 3 Steerin angle sensor CUTF 5 ABS Cut valve relay (front) J05 DRC-16- 70 Intermediate connector AA-5 RTR DT2 2 Retarder oil temperature sensor (right) I-9
70PAE
ASR2 2 Shut-off solenoid N-2 CUTR 5 ABS Cut valve relay (rear) S01 DT2 2 Service brake switch C-7
J06 DT06-4S 4 Intermediate connector AA-5
ASR3 2 ASR valve (right) M-3 D01 AMP 2 Diode Y-8 S02 DT2 2 Secondary brake swtich F-9
J07 DT2A 12 Intermediate connector L-9
ASR4 2 ASR valve (left) M-3 D02 AMP 2 Diode Y-8 S03 DT2 2 Front brake cut valve F-9
J08 DT2B 12 Intermediate connector M-8
ASR5 2 ASR oil pressure switch (right) M-3 D03 AMP 2 Diode Y-9 S04 DT2 2 Auto suspension solenoid 1 (if equipped) G-9
J13 12 Intermediate connector
ASR6 2 ASR oil pressure switch (left) M-3 D04 AMP 2 Diode Z-8 S05 DT2 2 Auto suspension solenoid 2 (if equipped) G-9
J1939 DT2 3 Connector -
ASR7 2 ASR oil pressure switch (Main) L-1 D05 AMP 2 Diode Z-8 SBP DT2 4 Bypass valve position sensor AI-6
J2P DRC26-50S- 50 Engine controller AN-7
ASS DT2 2 Air suspention seat (if equipped) D06 AMP 2 Diode Z-8 04 SBS DT2 2 seat belt switch
ATC1 DRC_keyA 24 Transmission controller AC-4 D07 AMP 2 Diode S-1 J3P DT06-4S 4 Engine controller AM-6 SDE M 6 Side lamp switch (if equipped) W-1
ATC2 DRC_keyA 40 Transmission controller AC-4 D08 AMP 2 Diode Y-8 JASR 6 Joint connector SEGR DT2 4 EGR valve position sensor AI-7
ATC3 DRC_keyB 40 Transmission controller AD-3 D09 AMP 2 Diode Y-2 Centralized SF1 DT2 12 Shift lever
JB1 Centralized terminal AJ-8
ATC6 X 4 Intermediate connector AE-2 D10 AMP 2 Diode Y-3 terminal SF2 DT2 2 Shift lever
B Terminal 1 Starting switch B terminal P-9 D11 AMP 2 Diode Y-3 Centralized SLL M 2 Side lamp (left) J-2
JB2 terminal Centralized terminal AK-9
B01 DT2 6 Intermediate connector L-9 D12 DT2 2 Diode M-7 SLR 2 Side lamp (right) D-8
JCA SWP 16 Joint connector AF-2
B02 DT2 6 Turn signal,tail,stop lamp (right) L-8 DL DT2A 12 Intermediate connector AE-2 SPA DT2B 12 Intermidiate connector M-7
JCB SWP 8 Joint connector AF-1
B03 DT2 6 Turn signal,tail,stop lamp (left) K-9 DPC1 AMP070 20 Monitor panel S-9 SPARE X 4 Junction connector AG-2
JCC SWP 16 Joint connector U-1
B04 M 2 Back lamp (70W) DPC2A AMP070 18 Monitor panel S-8 SPL 2 Speaker (left) H-9
JCD SWP 16 Joint connector T-1
B05 Terminal 1 Back alarm buzzer K-9 DPC2B AMP070 12 Monitor panel R-8 SPR 2 Speaker (rigth) G-9
JCE SWP 8 Joint connector T-1
B06 Terminal 1 Back alarm buzzer K-9 DPC3A AMP070 18 Monitor panel R-8 SR3 X 3 Steering speed sensor R-1
JCF SWP 16 Joint connector T-1
B07 DT2 3 Body positioner sensor J-9 DPC4 AMP070 12 Monitor panel S-9 ST1 Terminal 1 Emergency steering switch O-2
JRE DT2 8 Intermediate connector
B1 DT2 2 Lamp G (right) (for payload meter) (if equipped) D-8 DPC6 AMP070 8 Intermediate connector R-8 ST2 Terminal 1 Emergency steering switch O-2
LKO DT2 2 Lever kick-out solenoid
B10 Terminal 1 Ground M-8 DPC7 X 4 Intermediate connector Q-2 ST3 Terminal 1 Emergency steering switch O-2
LM1 - 1 Download box
B1L DT2 2 Lamp G (left) (for payload meter) (if equipped) L-3 DSL 1 Door switch (left) G-1 ST4 Terminal 1 Emergency steering switch O-2
LM2 - 1 Download box
B2 DT2 2 Lamp A (right) (for payload meter) (if equipped) D-7 DSR 1 Door switch (right) D-7 STR DT2 2 Steering oil temperature sensor (if equipped) K-3
LP1 DT2 12 Intermediate connector H-1
B2L DT2 2 Lamp A (left) (for payload meter) (if equipped) L-3 DT7 DT2 12 Intermediate connector X-2 SUFL DT2 3 Suspension oil pressure sensor (front,left) (if equippe) H-1
LS 3 Reostat V-1
B3 DT2 2 Lamp R (right) (for payload meter) (if equipped) D-7 DT8 DT2 4 Intermediate connector X-2 SUFR DT2 3 Suspension oil pressure sensor (front,right) (if equipped) C-6
MON AMP 4 Back monitor (if equipped) Q-8
B3L DT2 2 Lamp R (left) (for payload meter) (if equipped) M-3 E01 Terminal 1 Alternater R terminal AK-5 SURL DT2 3 Suspension oil pressure sensor (rear,left) M-8
NE FRAMATOME 3 Ne sensor AI-2
BCVR X 2 BCV solenoid (right) J-9 E02A DT2 2 Starting relay AL-1 SURR DT2 3 Suspension oil pressure sensor (rear,right) K-9
OP7_M 1 Junction connector U-1
BK DT-T 12 Intermediate connector G-9 E02B DT2 2 Starting relay AL-1 T05 Terminal 1 Ground K-2
_F 1 Junction connector U-1
BLS M 6 Rotary lamp switch E04 DT2 2 Engine oil level switch AL-5 T1 Terminal 1 Ground AG-9
OPS DT2 2 Operator seat heater
BP DT2 2 BP valve AI-6 E05 Terminal 1 Oil filter switch D-2 T10 Terminal 1 Ground B-4
ORB-A - 14 Orbcom controller (if equipped)
BR Terminal 1 Starting switch BR terminal P-8 E06 Terminal 1 Alternater E terminal AK-5 T20 Terminal 1 Ground K-2
ORB-B - 10 Orbcom controller (if equipped)
BRC1 DRC_keyA 24 Retarder controller AE-3 E07 X 2 Air compressor AK-5 TCHET X 4 Tacho graph & heater unit P-7
PAMB AMP 3 Ambient pressure sensor AN-7
BRC2 DRC_keyA 40 Retarder controller AE-3 E09 Terminal 1 Alternater B terminal AK-5 TEST_F 1 ASR test swtich AG-1
PCV1 SUMITOMO 2 Supply pump control valve AN-8
BRC3 DRC_keyB 40 Retarder controller AE-3 E11B Terminal 1 Heater relay D-9 TEST_M 1 ASR test swtich AG-1
PCV2 SUMITOMO 2 Supply pump control valve AN-8
BRC6 X 4 Intermediate connector AE-2 E12B Terminal 1 Heater relay D-9 TFUEL PACKARD 2 Fuel temperature sensor AJ-5
PDL - 5 Download box
BT DT2B 8 Intermediate connector D-9 E14 Terminal 1 Starting motor B terminal AK-1 TIM PACKARD 2 Boost temperature sensor AN-8
PFUEL AMP 3 Common rail pressure sensor AK-9
BT1 20 Fuse box AH-3 E15 Terminal 1 Ground D-2 TM2 HD-95995 23 Intermidiate connector AH-8
PIM SUMITOMO 3 Boost pressure sensor AN-8
BT-1A Terminal 1 Battery1 (+) F-9 E16B Terminal 1 Ground D-9 TM3 HD-95995 31 Intermidiate connector AH-8
PL01 M 2 Head lamp (Hi) (left) F-1
BT-?B Terminal 1 Battery1 (-) E-9 E16E Terminal 1 Ground D-9 TMF1 DT2 2 Transmission oil filter switch
PL02 M 2 Head lamp (Lo) (left) E-1
BT2 30 Fuse box AH-3 E17B DT2 2 Diode C-9 TOIL PACKARD 2 Engine oil temperature sensor AM-6
PL03 M 3 Front combination lamp (left) F-1
BT-2A Terminal 1 Battery2 (+) F-9 E80 Terminal 1 Ground AM-6 TWTR PACKARD 2 Engine coolant temperature sensor AI-2
PL04 - 1 Beacon lamp (left) E-1
BT-2B Terminal 1 Battery2 (-) F-9 EG4 DT2D 12 Intermediate connector Y-2 VDL - 5 Download box
PL06 M 2 Fog lamp (left) (if equipped) E-2
BT3 30 Fuse box AH-3 EGR DT2 2 EGR valve AI-7 VHMS - 5 Intermidiate connector
PL07 Terminal 1 Ground C-2
BT4 20 Fuse box AH-3 EM 2 Emergency steering timer AH-2 WFM 6 Wiper motor (front) S-1
PLM - 5 Intermediate connector
BTL DT2 2 Intermediate connector C-7 EMPR - 2 Emergency steering Fuse C-9 WFR 6 Wiper relay (front) U-1
PM1 MIC_S 21 Intermediate connector V-9
BZ2 M 2 Buzzer U-1 ENG DRC 60 Engine controller AN-6 WPS DT2B 12 Wiper switch Q-2
PM11 MIC 20 Intermediate connector Y-9
C Terminal 1 Starting switch C terminal P-9 EP - 2 Electrical priming pump AM-6 WSR 4 Intermidiate connector
PM3 DT2 3 Pitch angle sensor AH-1
CAB1 DT2A 8 Intermediate connector V-9 EPF - 2 Fuse (20A) D-8 WSRL 2 Wheel rotation sensor (left) M-1
PM4 S 16 Intermediate connector V-9
CAB2 DT2B 8 Intermediate connector U-9 EPTS - 6 Electrical priming pump timer switch D-2 WSRR 2 Wheel rotation sensor (right) M-1
PM5 - 13 Payload meter controller (if equipped)
CAN1 DT2 3 Intermediate connector W-9 ER Terminal 1 Ground H-9 53 Terminal 1 Emergency steering relay B-8
PM6 - 12 Payload meter controller (if equipped)
CAN2 DT2 3 Resistor T-1 ER1 Terminal 1 Ground Z-8
PM7 - 9 Payload meter controller (if equipped) aDetails of colored connectors
CAN2 DT2 3 Terminal resistor (120Ω) I-9 ER1 Terminal 1 Ground
PM8 - 5 Intermediate connector DT2A:Gr (Gray), DT2B:B (Black), DT2C:G (Green), DT2D:Br (Brown)
CG1_F M 2 Cigarette lighter P-7 ER2 Terminal 1 Ground
PMLA DT2A 12 Intermediate connector H-9
CH1 M 8 Mode selector switch 1 V-1 ER3 Terminal 1 Ground Q-7
PMRA DT2 6 Intermediate connector E-8
CH2 M 8 Mode selector switch 2 V-1 EXH M 6 Exhaust break switch AA-2
POIL FRAMATOME 3 Engine oil pressure sensor AL-5
CHECK M 6 ABS check switch X-2 FBC M 6 Front brake cut switch AA-2
PR01 M 2 Head lamp (Lo) (right) B-5
CJA DT2 6 Joint connector C-7 FL02 DT2 2 Radiator coolant lebel sensor C-3
PR02 M 2 Head lamp (Hi) (right) B-4
CJB DT2 6 Joint connector B-6 FL04 2 Washer moter C-3
PR03 M 3 Front combination lamp (right) B-5
CJC DT2 6 Joint connector B-6 FL06 DT2 3 Ambient temperature sensor F-1
PR04 M 2 Beacon lamp (right) B-5
CJD DT2 6 Joint connector B-6 FLS 4 Flasher V-1
PR06 M 2 Fog lamp (right) (if equipped) B-5
SEN01106-06
HD465-7E0, HD605-7E0 23
HD465-7E0, HD605-7E0 25

© 2009 KOMATSU
All Rights Reserved
26 HD465-7E0, HD605-7E0

HD465-7E0 Shop Manual PDF

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HD465-7E0 Shop Manual PDF

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SEN01081-12

DUMP TRUCK HD465 -7E0

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual .......................................................................................................................... 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01081-12

00 Index and foreword SEN01082-12

10 Structure, function and maintenance standard SEN01087-07

20 Standard value table SEN01100-03

30 Testing and adjusting SEN01101-05

General information on troubleshooting SEN01661-05

50 Disassembly and assembly SEN01103-04

90 Diagrams and drawings SEN01104-08

Foreword and general information SEN01084-06

10 Structure, function and maintenance standard

Front brake off valve ................................................................................................................... 9

30 Testing and adjusting

Testing air supply pressure (boost pressure) .............................................................................. 11

Failure code [CA442] Battery voltage high error ......................................................................... 9

Failure code [DBB6KP] (or VHMS_LED display: “n9” o “02”)

Failure code [DHE5KB] (or VHMS_LED display: “n3” o “32”)

Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”)

50 Disassembly and assembly

Hydraulic system SEN02490-01

90 Diagrams and drawings

HD465-7E0, HD605-7E0 Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

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 or allow-

Handling of 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

q When removing a connector from a