HD465 7 Shop PDF

SEBM027609
MACHINE MODEL SERIAL NUMBER
HD465-7 7001 and up

HD605-7 7001 and up
• This shop manual may contain attachiments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• HD465-7, HD605-7 mount the SAA6D170E-3 engine.

For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Japan 12-04(02) 00-1
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CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1
10 STRUCTURE, FUNCTION AND

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

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20-1113 (2) 30-9 (3) 30-60 (3) 30-111 (8) 90-3
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20-1119 (2) 30-15 (3) 30-66 (3) 30-114 (3) 90-15
20-1120 (2) 30-16 (3) 30-67 (3) 30-115 (8) 90-17
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30-5-2 (8) 30-55 (3) 30-106 (3) 30-151 (4)
30-5-3 (4) 30-56 (3) 30-107 (3) 30-152 (4)
30-6 (3) 30-57 (3) 30-108 (3)
30-7 (3) 30-58 (3) 30-109 (3) 90-1 (2)
30-8 (3) 30-59 (3) 30-110 (8) 90-2
HD465-7, HD605-7 00-2-5

(9)
01 GENERAL
Specification drawings....................................... 01- 2

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

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

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

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

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

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

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

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

Max. torque Nm/rpm{kgm/rpm} 3,256/1,400 {332/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 207 {154}
Stating motor 24V, 7.5 kW × 2 units
Alternator 24V, 75A
Battery 12V, 200Ah × 2 units
HD465-7, HD605-7 01-3

Structure 3-element, 1-stage, 2-phase

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

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

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

Suspension
Axle type
Rear axle Full floating
Front axle Hydropneumatic

Suspension method
Rear axle Hydropneumatic
Front tire 24.00 – 35 – 36PR × 2

Size and No.
Tires
Rear tire 24.00 – 35 – 36PR × 4
Tire pressure Front and rear tire kPa {kgf/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
Parking brake Multiple disc wet type disc brake,

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

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 604

Hoist cylinder
Type 2-stage piston type

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

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

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

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

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

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

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

Max. torque Nm/rpm{kgm/rpm} 3,256/1,400 {332/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 207 {154}
Stating motor 24V, 7.5 kW × 2 units
Alternator 24V, 75A
Battery 12V, 200Ah × 2 units
01-6 HD465-7, HD605-7

Structure 3-element, 1-stage, 2-phase

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

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

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

Suspension
Axle type
Rear axle Full floating
Front axle Hydropneumatic

Suspension method
Rear axle Hydropneumatic
Front tire 24.00 R35 ★★ × 2

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

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

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

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

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

Hydraulic system
For brake cooling
Type Gear pump
Delivery /min 604

Hoist cylinder
Type 2-stage piston type

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

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

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

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

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

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

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

Fuel tank
case system
Specified oil 32 each for

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

— —
( ) right and left
Fuel and oil

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

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

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

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

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

(9)
RADIATOR, TORQUE CONVERTER
OIL COOLER, AFTER COOLER, WORK
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EQUIPMENT OIL COOLER, FUEL COOLER
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER

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

2. Upper tank Radiator
3. Lower tank Core type: CF4-5
(torque converter oil cooler built in) Total radiation surface: 130.6 m2
4. Core
5. Work equipment oil cooler Work equipment oil cooler
6. After cooler Core type: CF40-1
7. Fuel cooler Radiation surface: 2.90 m2
A : Cooling water inletl port Fuel cooler

B : Cooling water outlet port Core type: FC1-3
Heat radiation area: 6.75 m2
HD465-7, HD605-7 10-3

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

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

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

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

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

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

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

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

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

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

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

6 Backlash at spline
0.080 – 0.231 0.4
Standard backlash
Original dimension: Lo
(Dimension at smallest width: L) Replace
Defomation of rubber cushion
7 90 81
75 67
External Without cranks
HD465-7, HD605-7 10-7

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

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

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

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

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

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

1. Coupling 10. Stator shaft

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

10-12 HD465-7, HD605-7

Unit: mm

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

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

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

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

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

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

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

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

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

(9)
Unit: mm

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

2 32 0.081
spoon and body –0.045 0 0.061

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

4 137 93.5 132.9
spring {33.8 kg} {32.1 kg}
Poppet spring (T/C relief, 32.0 N 30.8 N

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

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

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

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

10-20 HD465-7, HD605-7

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

10-22 HD465-7, HD605-7

Unit: mm

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

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

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

8 35.0 ±0.26 32.3

9 36.6 ±0.26 33.9

10 47 ±0.30 43.7
Replace
11 44.8 ±0.28 42.1

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

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

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

Unit: mm

Wear of No. 2 and Width –0.01

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

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

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

26 0.15 – 0.39

27 0.14 – 0.36

28 0.13 – 0.34
etary gear and planetary gear

29 0.15 – 0.39

30 0.16 – 0.41

31 0.16 – 0.41

32 0.13 – 0.36

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

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

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

Unit: mm

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

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

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

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

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

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

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

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

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

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

(9)
ECMV FOR LOCKUP CLUTCH

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

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

(9)
WHEN THE TORQUE CONVERTER IS OPERATING

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

(9)
ECMV FOR SPEED RANGE CLUTCH

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

tics of proportional solenoid
ECMV and fill switch

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

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

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

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

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

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

(9)
ECMV FOR SPEED RANGE CLUTCH

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

tics of proportional solenoid
ECMV and fill switch

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

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

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

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

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

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

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
REAR
1. Differential Specifications
2. Axle housing Reduction ratio
3. Brake Differential: 3.538
4. Final drive Final drive : 4.737
Oil
Differential: EO30-CD (95 liters)
Final drive : EO30-CD (32 liters each side)
Tire size : 24.00-35 (HD465-7)
24.00R35 (HD605-7)
Rim size: 17.00-35
HD465-7, HD605-7 10-41

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm

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

8 6 5.5 Replace
washer –0.050
Backlash between bevel gear

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

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

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

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

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

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

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

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

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

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

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

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

(6)
Unit: mm

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

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

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

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

(6)
Structure and operation

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

(6)
c. Variable shaft mechanism

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

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

(6)
Unit: mm

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

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

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

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD REAR AXLE SUPPORT
REAR AXLE SUPPORT
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
10-56 HD465-7, HD605-7

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

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

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

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

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

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

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

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

(6)
Unit: mm

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

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

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

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

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

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

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

13 70 0.3
Clearance between center

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

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

16 40 0.3
Clearance between suspen-

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

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

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

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

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

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

(6)
Operation Applying brake when upper valve fails

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

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

(6)
Lower portion Brake released

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

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

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

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

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

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

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

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

(6)
Operation 2. When oil supplied to accumulator

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

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

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Front brake
Gas used : Nitrogen gas
Charge amount : 3,500 cc
Charging pressure: 11.8 MPa {120 kg/cm2}
Rear brake, Parking brake

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

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

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

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

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

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

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

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

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

(6)
Unit: mm

Wear of pad (remaining thick-
4
ness of wear material) 19.5 3.0
Replace
5 Missing portion of pad – Ratio of surface: 10%
Co r re c t o r
6 Face runout of disc (Note 1) 0.15 0.50
replace
Wear of disc
7 30 Less than 27
(thickness of disc)
Replace
Open crack in radial direction
8 Damage to disc surface –
Electric wear, marked damage (Note 2) Correct
Note 1: • If there is excessive face runout of the disc, check the front wheel bearing also.
Note 2: • If the depth of the scratch exceeds 1.5 mm.
• If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or
there is protrusion.
• If there are vertical scratches other than concentric scratches.
HD465-7, HD605-7 10-79

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

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

11
and plate 0.21 – 0.64 2.2
Backlash between inner gear

12 0.21 – 0.64 2.2
and disc

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

17
surface Max. 0.45 0.7
Warping of plate and damper

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

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

(6)
Function Operation of parking brake

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

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

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

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

(6)
STEERING AND HOIST
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
1. Cross-over relief valve

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

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

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

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

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

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CONTROL VALVE
STEERING CONTROL VALVE
1. Input shaft 8. Ball a : From demand valve (P port)

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

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

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

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

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

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

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

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

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

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

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

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

P1 : From hydraulic pump

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

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

Installed
Free length Installed load Free length Installed load
12 Spool return spring length
130.4 N 120.6 N Replace

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

Function circuit directly through the port D.

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

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

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

STEERING RELIEF VALVE

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

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

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

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

Free length Installed

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

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

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

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

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

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

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

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

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

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

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

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

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING • HOIST + HOIST CONTROL
SAR(3)100+100+(1)6
Unit: mm

Model Standard clearance Clearance limit
SAR(3)-100
1 Side clearance 0.10 – 0.15 0.19
SAR(3)-100
SAR(1)-6 0.10 – 0.15 0.19
Clearance between inside SAR(3)-100
diameter of plain bearing and 0.060 – 0.149 0.20
2 SAR(3)-100
outside of diameter of gear Replace
shaft SAR(1)-6 0.06 – 0.144 0.20
Model Standard size Tolerance Repair limit
SAR(3)-100 0
13
3 Depth for knocking in pin SAR(3)-100 –0.5
–
0
SAR(1)-6 10
–0.5
4 Rotating torque of spline shaft 5.8 – 28.5 Nm {1.6 – 2.9 kgm}
Standard
Rotating Delivery pres- Delivery
delivery
Model speed sure amount limit
amount
Discharge amount (rpm) MPa {kg/cm2} ( /min)
( /min) –
– Oil: EO10-CD
Oil temperature: 45–55°C SAR(3)-100
184 170
SAR(3)-100 2,500 20.6 {210}
SAR(1)-6 13.2 12.6
10-110 HD465-7, HD605-7

RETARDER COOLING PUMP

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

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

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

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

TORQUE CONVERTER, TRANSMISSION + RETERDER COOLING, BRAKE

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

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

EMERGENCY STEERING PUMP

SBL(1)-014
Unit: mm

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

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

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

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

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

(9)
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper

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

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

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

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

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

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

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Network data
1. From machine monitor to each controller
• Switch input data
• Option setting data
2. From each controller to machine monitor
• Display data related to each controller
• Service mode data
• Troubleshooting data
3. From transmission controller to machine monitor
• Model selection data
HD465-7, HD605-7 10-119

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

(6)
MACHINE MONITOR
1. Speedometer 24. Seat belt caution lamp

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

(9)
41. Travel speed compensation switch [SW1]

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

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

58. Setting connector [OP7]
ADJUSTING MACHINE MONITOR

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

MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
: Lighted up : Discontinuous sounds

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

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

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

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

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

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

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

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

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

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

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

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

(9)
Related When
Central switch is turning
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Reverse
travel
integrating
meter Display Switch screen
Reset of character: Press machine by operating
time to black monitor mode machine
Other selector switch For details, see the
displays change fil- LCD Back- monitor mode instruction manual.
ter and oil. ground " " selector
Telephone color: switch
7 number green ">" or "<".
setting
Language
selection
Dimmed down
Night When the by a step
lighting Backlight LED Green small lamp is when the — —
lit up. small lamp is
lit up.
Central During system is Lit up during
8 warning LED Red abnormal warning.
lamp
Note 1:The moment

when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
Mainte- nance-related has been given
13 nance LED Red alarm is given or Lit up or turn   appear on the
warning the time to ON and OFF character
change filter and display.
oil has elapsed. Note 2:For details on
the target items,
etc., see the
instruction
manual.
Battery
During battery
charging Lit up during
14 LED Red charging circuit
circuit warning.
being abnormal
warning
Steer-
ing oil When the
tempera- Warning steering oil Lit up during
15 LED Red
ture temperature warning.
warning rises.
(option)
Engine
When the engine
oil pres- Lit up during
16 LED Red oil pressure
sure warning.
drops.
warning
Retarder When the
Lit up during Operates when the
oil pres- retarder
17 LED Red being abnor- alternator R terminal is
sure oil pressure (Note) (Note)
mal. ON.
warning drops.
Operates when the
Parking When the parking brake is oper-
Lit up during
18 brake LED Red parking brake is ated and the shift lever
operation. (Note) (Note)
warning operated. is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up during tions, used in the event
19 LED Red machine monitor
optional warning. of failure of the
or optional
system machine monitor.
controller system
warning
During being
Engine
abnormal in Lit up during
20 system LED Red
engine control warning.
warning
system.
10-126 HD465-7, HD605-7

(9)
Related When
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Trans-
Being abnormal
mission Lit up during
21
system
LED Red in transmission
warning.
control system
warning
During being
Retarder
abnormal in Lit up during
22 system LED Red
retarder control warning.
warning
system
When the body is
Inclina-
lifted and inclined Lit up during
23 tion LED Red
excessively warning.
warning Warning from side to side.
During
operation:
Seat-
When the seat- lit up
24 belt LED Red — —
belt is not worn. During non-
warning
operation:
turned OFF.
During
See the operation: Note: Operates when
Body lit up the shift lever is in
25 LED Red instruction
warning manual During non- (Note) (Note) other than the "N"
operation: position.
turned OFF.
During
Emer- When the emer- operation:
26 gency LED Red gency steering is lit up  
steering operated. During non-
operation:
turned OFF.
During
Turn operation:
lit up
27 signal, LED Green During operation During non- — —
right operation:
turned OFF.
During
Turn operation:
lit up
28 signal, LED Green During operation During non- — —
left operation:
turned OFF.
During
Head- operation:
light, lit up
29 LED Blue During operation During non- — —
high
beam Pilot operation:
turned OFF.
Shift
30 When the shift
lever
LED Green lever is in the "R" Lit up (*) — — * Blinks when the neu-
(R) position position tral safety is operated.
R
Shift
30 When the shift
lever
LED Orange lever is in the "N" Lit up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lit up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift
lever
LED Green lever is in the "6" Lit up (*) — — * Blinks when the neu-
(6) position tral safety is operated.
position
6
Shift
30 When the shift
lever
(5) position tral safety is operated.
position
5
HD465-7, HD605-7 10-127

(9)
Related opera- When

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

(9)
Related opera- When

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

(9)
Self-diagnostic function when operating starting

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

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

OUTLINE OF SERVICE MODE

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

3) Real-time monitor
This function is used when checking the
input and output signals recognized by the
controllers on the network.
The real-time monitor display on the charac-
ter display is as shown below.
*** : Displays name of item
##### : Displays ID No. given to each item
%%% : Displays data. If units are used, the
unit is displayed on the right side of
the data By specifying the ID No.
given to each item, it is possible to
display the desired 2 items at the
same time. The character display
when a second item is displayed at
the same time is as shown below.
##### : Displays specified ID No.
%%% : Displays data. If units are used, the-
unit is displayed on the right side of
the data
4) ECMV compensation
For details of this function, see TESTING
AND ADJUSTING, Adjusting transmission, 2.
ECMV compensation.
5) Changing filter, oil replacement time
For details of this function, see the Operation
and Maintenance Manual, OPERATION,
Character display portion, Filter, oil replace-
ment time display. This is used when chang-
ing the replacement interval.
6) Snapshot function
When the VHMS controller is installed, this
menu is displayed.
For details, see "TESTING AND ADJUST-
ING, [Items related to PM Clinic], Execution
of Pm Clinic with Manual Snapshot (another
name: Quick PM)".
7) PLM setting function
When payload meter (having VHMS) is set
optionally, this menu is displayed.
For details, see "STRUCTURE, OPERA-
TION, and MAINTENANCE STANDARD,
Payload meter (having VHMS)".
8) Controller initialize
This function is used only at the factory, so
do not touch it.
9) Setting service meter
This is used when replacing the machine
monitor with a new part, and setting the
appropriate service meter reading for the
machine. For details of the method of opera-
tion, see TESTING AND ADJUSTING, Adjust-
ing machine monitor.
10) Setting travel distance total
appropriate travel distance total value for the
machine. For details of the method of opera-
tion, see TESTING AND ADJUSTING, Adjust-
ing machine monitor.
11) Setting reverse travel distance total
appropriate reverse travel distance total
value for the machine. For details of the
method of operation, see TESTING AND
ADJUSTING, Adjusting machine monitor.
10-132 HD465-7, HD605-7

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

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

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

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

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

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

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

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE

• The relationship between each gearshift position and the automatic gearshifting range is as as shown in the
table below.
Gearshifting characteristics Power mode:

• Shifting the transmission up and down is carried The power mode uses the power of the machine to
out according to the shift map saved in the con- the maximum to provide the maximum payload.
troller memory.
There are three types of shift map, depending on Economy mode:
the condition of the input signals. When the machine is being used under light load,
The settings for each mode are as shown in the such as when traveling unloaded or on flat ground,
table below. the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower
Mode Set conditions level, and the fuel consumption, noise, and trans-
mission shock are improved.
When either of the following conditions is
fulfilled
Braking
1. Brake signal ON
mode
(footbrake, retarder brake operated)
2. Accelerator pedal released
When the following three conditions are

fulfilled
1. Brake signal OFF
Power mode
(footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at high power
When the following three conditions are

fulfilled
Economy 1. Brake signal OFF
mode (footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at economy
Braking mode:
The shift-down point and the shift-up point are both
raised, the engine speed is maintained at a higher
level, and the amount of cooling oil for the retarder is
ensured to provide greater effect when the engine is
used as a brake.
10-144 HD465-7, HD605-7

AUTOMATIC GEARSHIFTING GRAPH

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

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

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

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

tion may differ according to the travel conditions.
For details, see the automatic gearshifting graph.
2) Gearshift lever positions 6, 5, 4, 3, 2, 1

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

Safety functions 6) Speed range limit function when dump body is

1) Down-shift inhibition function raised.
If gearshift lever is operated D → 6-L, 6 → 5-L, 5 After dumping the load, if the body is not com-
→ 4-L, 4 → 3-L, 3 → 2-L, 2 → L pletely lowered, shifting up is limited.
For example, when traveling in D (F6), even if If the gearshift lever is at D, the machine starts in
the gearshift lever is operated to 4, the transmis- F2, and if it is at positions 6 to L, the machine
sion does not shift directly F6 → F4. It shifts starts in F1. The transmission does not shift up
down F6 → F5 → F4 in turn according to the until the body is completely lowered.
travel speed.
(The transmission does not jump two speed Self-diagnostic function
ranges if the operator makes a mistake when The controller carries out self-diagnosis of the sys-
operating the gearshift lever. This is to prevent tem and displays any abnormalities.
the engine from overrunning.) If any abnormality is detected by the self-diagnosis
2) Neutral safety function function, the abnormality data is transmitted to the
This circuit prevents the engine from starting if network and is displayed as an action code on the
the gearshift lever is not at the N position, even if machine monitor. The transmission system caution,
the starting switch is turned to the START posi- warning lamp, or alarm buzzer may also be actu-
tion. ated.
(This is a safety circuit to prevent the machine
from moving unexpectedly when the engine is
started.)
3) Directional inhibition function
When traveling forward at a speed of more than
4 km/h, even if the gearshift lever is operated to
positions R, the transmission will not be shifted
immediately to travel in reverse. The speed
range is shifted to N and the engine speed is
lowered to reduce the travel speed. When the
travel speed goes below 4 km/h, the transmis-
sion is shifted to REVERSE.
(To prevent overload on power train, to improve
durability and reliability)
4) Power train overrun prevention rear brake func-
tion
When the engine speed exceeds 2,500 rpm in
high-speed mode or 2,400 rpm in low-speed
mode, the central warning lamp flashes and the
warning buzzer sounds.
When the engine speed exceeds 2,600 rpm in
high-speed mode or 2,450 rpm in low-speed
mode, the rear brake is activated automatically.
(To prevent overrun of engine, torque converter,
and transmission, to improve durability and reli-
ability)
Condition in which high speed mode can be
selected: Any of coditions below is sattisfied
(1) Shifting up is possible
(2) Gear shift is placed in any of F7, N, and R
positions
Condition in which low speed mode can be
seleced: In the condition other than high speed
mode
5) REVERSE safety
The machine will not travel in reverse if the dump
control lever is not at FLOAT and the dump body
is not completely lowered.
(Turnover prevention function)
HD465-7, HD605-7 10-147

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

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

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

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

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

(6)
PRINCIPLE OF CALCULATION
1. Outline
A dump truck is supported by 4 suspension cylin-
ders. By measuring the total of the loads on
each cylinder, it is possible to know the load
mass on the springs of the dump truck.
The measurement of the load mass is obtained
by calculating the difference between the mass
when empty and the mass when full.
The load on each cylinder can be calculated
from the internal pressure and sectional area of
the suspension cylinder.
[Load bearing on suspension cylinder]
W = PB SB – PT (SB – ST)
Where
W = Load bearing on suspension cylinder
PB = Bottom pressure
PT = Top pressure
SB = Cross-sectional area of cylinder
ST = Cross-sectional area of rod
Because of the structure of the suspension cylin-

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

(6)
2. Measurement of mass when empty

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

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

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

(6)
FEATURES OF EACH DEVICE

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

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

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

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

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

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

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

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

(6)
Payload meter has the following basic functions.

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

(6)
ii) Measuring empty mass (calibration)

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

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

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

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

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

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

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

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

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

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

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

(6)
Engine ON/OFF data

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

load mass value setting
1) Load mass fixed display
When displaying the load mass in the range
shown in the table below, it is possible to input
and correct to set the display for the load mass
when loading is completed (when loading at
least 50% of set load mass and traveling 160
m and starting to dump), not the real-time
load mass.
Setting Range Payload fixed display
The time that machine is Load mass when stopped in
stopped when loading at least previous cycle
TALKS not set
50% of set load mass and
(option codes 0 – 3, 10, 11 set)
traveling 160 m and starting
to dump
When there is per- The time that machine is Load mass last displayed in
mission to start stopped from permission to previous cycle
move off to starting to dump (Final radio transmission
TALKS set value)
 option codes 
The time that machine is Load mass last displayed in
 4 – 9 set  When disconnection
stopped from disconnection previous cycle
of line from payload
of line to starting to dump
meter is requested
2) Switching load mass fixed display in cycle data

recording
If the load mass fixed display in Item 1) above
is applicable, it is possible to input and correct
the data to set the load mass inside the cycle
data in Item 6-1 to the fixed display load mass
value.
Possible set range: 00, 01, 10
Possible set value table
Display Load mass fixed display Recorded load mass value
00 Yes Load mass fixed display value
01 Yes Value when dumping load
10 No Value when dumping load
Loading completion recognition travel distance set-

ting
This is used to input and correct the values to set
the travel distance recognized as completion of
loading by payload meter .
Possible set range: 0 – 255 (m)
Loading start recognition load mass setting

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

(6)
Zero ton display range setting

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

This is used to input and correct the values
to set the lamp display load mass range
when displaying the load mass.
Possible set range:
Lamp 1 (green) A : 510 – 255
Lamp 2 (yellow) B : A – 255
Lamp 3 (red) C : B – 255
The set value is displayed as a propor-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

repeats sequence
All displayed values are rounded to

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

(6)
Operation for input signal condition display Operation for data all clear (service area)
Set to CHEC display, then press Set to CHEC display, then press
switch
switch and .
Display: Cd : dP
Display: A : CLE
Press switch again.
Press switch .
The main display will go out and memory card
access lamp will light up. The display will become A.CLE (lighted up), and
When the memory card dump operation is com- when the data all clear operation is completed, it will
pleted, it will return automatically to the CHEC dis- return automatically to the CHEC display. (End)
play. (End)
If it is desired to stop the data all clear operation
If it is desired to stop the memory card dump opera-
when the display is A : CLE, presss witch
tion when the display is Cd : dP, press (3), and the display will return to CHEC without per-
switch , and the display will return to CHEC with- forming the data all clear operation.
out performing the memory card dump operation.
Before clearing the data, download the necessary
The memory card dump function can be used only data to a PC or carry out the card dump operation in
when the No. 5 switch (memory card use switch) on Item .
the left side of the controller is set to "Use".
HD465-7, HD605-7 10-169

Operation for memory card dump (service area) ( -a) Parking brake, brake lock switch signal condi-
tion [HD1200-1]
Display: C1:XX (lights up for 3 seconds)
Either one ON: CL : oo

Both OFF: CL : — —
↓
( -a’ Shift lever position signal condition [except
HD1200-1]
Display: C1: XX (lights up for 3 seconds)
"N": CL : oo
Except "N": CL : — —
↓
(2-b) Dump lever position signal condition
Set to CHEC display, then press Display: C2:XX (lights up for 3 seconds)
F. FLOAT: C2 : oo
switches and at the same time Except FLOAT: C2 : — —
for at least 2 seconds. ↓
(2-c) Engine oil pressure signal condition
Display: S : CHE Display: C3:XX (lights up for 3 seconds)
Engine running: C3 : oo
Every time switch is pressed, Engine stopped:C3 : — —
the display changes in the order shown on the ↓
right. Go to next page
If switch is pressed at any time

during the display in Steps or , the display
will return to CHEC. (End)
10-170 HD465-7, HD605-7

From previous page

↓
( -d) Battery charge signal condition ( -k) Payload meter present recognition display
Display: C4:XX (lights up for 3 seconds) Counter display
Engine running : C4 : oo
Engine stopped: C4 : — —
↓
( -e) Analog spare input 1 signal condition
Display: C5:XX (lights up for 3 seconds) Empty stopped.............. 03.01
X.X .... Input signal (V) Empty traveling ............. 01.02
↓ Loading ......................... 06.03
( -f) Analog spare input 2 signal condition Loaded traveling ........... 02.04
Display: C6:XX (lights up for 3 seconds) Loaded stopped ............ 04.05
X.X .... Same as C5 Dumping ....................... 05.06
↓
( -g) Digital spare input 1 signal condition Invariable May change
according to
Display: C7:XX (lights up for 3 seconds) N signal when
↓ dumping
Hi: C7 : oo ( -l) Machine condition time display shown below

Lo: C7 : — —
↓
( -h) Digital spare input 2 signal condition Every time switch is pressed,
Display: C8 : XX (lights up for 3 seconds)
the display advances one place in order from to
X.X .... Same as C7
↓ .
( -i) Travel speed display
Display: C9 : XX Empty traveling S1 :
X.X .... Travel speed (km/h) Empty stopped S2 :
↓ Loaded traveling S3 :
( -j) Travel distance display Loaded stopped S4 :
 Travel distance with machine in present  Dumping S5 :
 condition (empty or loaded) for that cycle  Loading S6 :
XXXX .... (m)
If the value goes above 9999m, the display starts

again from 0. The value for the
present machine
recognition con-
dition increases
in minutes in real
time.
HD465-7, HD605-7 10-171

Operation for performing forced initialization Operation for setting extra payload when loading
Set to CHEC display, then press Set to CHEC display, then press
switch and at the same time for

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

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

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

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

Operation for setting loading completion recognition travel distance

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

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

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

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

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

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

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

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

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

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

Operation for setting 0 ton display range
Set to P.SEL display, then press

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

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

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

Operation for setting display range of external Press switch again.

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

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

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

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

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

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

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

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

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

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

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
1 Dump lever at position — b-FL ON All flash When [for HD1200-1]
other than FLOAT removed When parking
(except when dumping) brake or brake
lock is ON
b-FL ON — When [for HD1200-1]
removed When parking
brake or brake
lock is OFF
2 Memory card — Cd flashes — When Removal detec-
removed removed tion only for card
dump
3 Drop in backup battery Defective contact F-09 flashes — When Except during
voltage or voltage below removed loading
2.7 V
4 Cycle data memory See (*1) See (*1) — See (*1) Except during
FULL loading
Engine ON/OFF data
memory FULL
Abnormality, warning
data memory FULL
Aggregate payload,
number of cycles data
memory FULL
5 Disconnection in Output below 2 V F-18 flashes All flash When When engine is
terminal R when engine is removed running
running
6 Abnormality in sensor Output is less than F-20 flashes All flash When Any time
power source (18 V) 15 V and power removed
source voltage is
more than 20 V
7 Short circuit with Suspension pres- F-21 flashes All flash When Any time
ground, disconnection sure sensor input removed
in front left suspension signal is 0 kg/cm2
pressure sensor system or below
8 Short circuit with F-22 flashes
ground, disconnection
in front right suspen-
sion pressure sensor
system
in rear left suspension
pressure sensor system
in rear right suspension
10-180 HD465-7, HD605-7

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

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

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

(000-020) performed when there is
abnormality

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

Order Error code display

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
11 Short circuit with Suspension pres- F-25 flashes All flash When Any time
power source in front sure sensor input removed
left suspension pres- signal is 19.6 MPa
sure sensor system {200 kg/cm2} or
12 Short circuit with more
F-26 flashes
power source in front
right suspension pres-
sure sensor system
power source in rear left
suspension pressure
sensor system
power source in rear
right suspension pres-
sure sensor system
15 Short circuit with Clinometer input F-31 flashes All flash When Any time
ground, disconnection signal above +100 removed
in clinometer system
16 Short circuit with power Clinometer input F-32 flashes
source in clinometer signal above –
system 100 EG
17 Calibration not per- Calibration data in F • CAL All flash When Any time
formed or abnormality in memory damaged flashes removed
RAM
18 Short circuit in external When coil is con- F-41 flashes See When Except when load-
display lamp No. 1 relay ducting electricity, Remarks removed ing (for external
relay coil short cir- column display lamps, see
19 Short circuit in external F-42 flashes
cuits with power Remarks column)
display lamp No. 2 relay
source
23 Defective cycle data See (*2) L.bad — Start of Start of dumping -
payload (*2) flashes empty travel start of empty
travel
24 Over speed limit Travel speed is SP:SP — Set value When problem
over set speed flashes – 2km/h occurs
limit
25 Defective communica- F-71 — When —
tions or defective setting F-73 removed
of option code F-80
F-81
F-91
F-92
F-93
F-94
F-95
F-96
F-97
F-98
F-99
10-182 HD465-7, HD605-7

Saving abnormality,
warning data (PC soft- Remarks
ware display code)
abnormality
(000-026)
(000-027)
(000-028)
Records Applicable only when

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

(000-019) stopped while problem
occurs
Records External display lamps
(000-041) actuated as follows
Applicable lamp
(000-042)
Machine stopped:
Always ON
(000-043) Machine traveling: OFF
Other lamps during load-
ing: Specified actuation
(000-044) Other than loading
Machine stopped: Flashes
Machine traveling: OFF
(000-045)
Records (000-071) —
(000-073)
(000-080)
(000-081)
(000-091)
(000-092)
(000-093)
(000-094)
(000-095)
(000-096)
(000-097)
(000-098)
(000-099)
HD465-7, HD605-7 10-183

AUTOMATIC EMERGENCY
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING SYSTEM
AUTOMATIC EMERGENCY STEERING SYSTEM
1. Timer Outline
2. Batter If the engine should stop when the machie is travel-
3. Flow switch ing, or there is any abnormality in the hydraulic pump
4. Emergency steering motor and the specified amount of oil does not flow to the
5. Emergency steering pump steering circuit, the emergency system automatically
6. Demand valve actuates an electric pump to ensure the hydraulic
pressure for the steering, thereby making it possible
to use the steering.
This system can also be operated manually.
★ Same machines have only manual operation.
10-184 HD465-7, HD605-7

AUTOMATIC EMERGENCY
FLOW SWITCH
1. Wire cable Outline

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

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

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

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

(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION SYSTEM
1. Dump control lever Outline

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

(6)
AUTOMATIC SUSPENSION MODE SELECTION CONTROL

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

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

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

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

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

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

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

(6)
7. Transmission of network data

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

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

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

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

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

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

(9)
RETARDER CONTROL FUNCTION

RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control

• The operating angle of the retarder lever is
detected by the potentiometer and a current cor-
responding to this is output to the electromag-
netic proportional valve to actuate the retarder.
Overrun prevention, retarder control when there

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

(6)
Relationship between retarder lever potentiometer

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

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

(6)
HOIST CONTROL FUNCTION

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

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

When the dump body is lowered and reaches the
position just before it is seated, the area of open-
ing of the EPC valve is throttled to control the
lowering speed of the dump body and reduce the
shock when the dump body comes into contact
with the chassis.
HD465-7, HD605-7 10-201

(6)
5. Float caution function

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

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

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

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

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

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

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

type
HD465-7, HD605-7 10-207

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

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

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

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

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

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

(6)
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
• When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (11) during the stroke. (Before start of actua-
tion of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
• When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion b
of rod (19) by retainer (13) that is being held by
detent spring (20).
• Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and pro-
trusion b of rod (19), so the lever is held at the
FLOAT position.
10-214 HD465-7, HD605-7

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

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

(6)
VHMS CONTROLLER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLOW-BY PRESSURE SENSOR
VHMS CONTROLLER
For details of the basic precautions, outlines,
method of sending and receiving data, and the
procedure for the initial setup, see TESTING
AND ADJUSTING (Drawing No. WJ021JD0500).
Specifications
1. Voltage of power supply : DC20V - DC30V
2. Size : W272 x D169 x H72
(mm)
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine con-
troller. It also gives commands for transmitting the
accumulated data through the communications sat-
ellite.
BLOW-BY PRESSURE
SENSOR
Specifications
1. Voltage of power supply : DC5V
2. Output voltage : 0.5V (engine stopped)
and up
3. Size: Mount (portion a) : R 1/4
: Outside diameter of
seat receiving pres-
sure : ø 37
: Length of cable:
1,110 mm
Function
The blow-by sensor converts the pressure inside the
engine crankcase into a voltage and inputs this into
the VHMS controller as the blow-by pressure.
10-216 HD465-7, HD605-7

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

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

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

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

(6)
EXHAUST TEMPERATURE SENSOR/AMP
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AMBIENT TEMPERATURE SENSOR
EXHAUST TEMPERATURE
SENSOR/AMP
Specifications
1. Rated voltage : DC24V
2. Detection temperature range : 100 – 1,000 °C
: 300 – 800 °C
(guaranteed accuracy ± 10 °C)
3. Output voltage characteristics: See table below
4. Actuation temperature range : --40 to 110 °C
5. Consumption current : Max. 30 mA
a : Heat sensing portion of sensor, outside diameter
of mount R 1/8
b : Amp
c : Connector (power source end)
d : Connector (sensor end)
Output voltage characteristics

(ambient temperature: 20 °C) ••• Reference value
Detection
temperature 50 100 400 700 800
(°C)
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
AMBIENT TEMPERATURE
SENSOR
Specifications
1. Electricity consumption : Max. 0.5 mW
2. Pressure resistance : 0.98 MPa
{10 kg/cm2}
3. Detected temperature range (surrounding)
: --30 to 120°C
4. Retention temperature range: --30 to 140°C
5. Performance table below
Detection
temperature --20 --10 0 10 20 50
(°C)
Resistance 30.32 18.58 11.74 7.623 5.077 1.712

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

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

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

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

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

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

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

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

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

(6)
ELECTRIC CIRCUIT DIAGRAM

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

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

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

The distance and travel speed are obtained from
the signals of the travel signal sensor of the
dump truck and the travel speed correction infor-
mation.
★ Travel signal sensor:
Transmission output shaft speed sensor
10-222 HD465-7, HD605-7

(6)
INITIAL SETTING OF PAYLOAD METER

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

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

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

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

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

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

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

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

load mass
If the load mass indicated by the payload meter
is different from that indicated by the user's load
meter, measure the operating mass (when the
truck is empty) and gross truck mass (when the
truck is loaded with the rated load mass) with the
user's load meter, then correct the relation table
of the suspension pressure and load mass forc-
ibly with the measured masses and this function.
3. Correction of level of inclination sensor

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

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

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

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

(6)
OPERATING METHOD
Select "PLM" in Service Mode 1 on the machine monitor.
For method of selection, see TESTING AND ADJUSTING, "Special functions of machine monitor (E MMS)".
HD465-7, HD605-7 10-225

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

HD465-7, HD605-7 10-235

(6)
FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES

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

(6)
• Distinction of communication control codes

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

(6)
• Automatic transmission
(a) Timing of transmission
The operation data of the concerned cycle are transmitted automatically when the concerned cycle data
are entered (when dumping is finished).
(b) Contents of communication
Format (VHMS controller External device)
STX (02h) [1] ETX (03h) BCC
[1]: Cycle data {39 bytes including header (ASCII L)}

Item Unit Range Number of byte Remarks
Header "L" ASCI1 1 L (Fixed)
Unused Integer 1 – 65535 2 0 (Fixed)
Month Month (BCD) 1
Day Day (BCD) 1
Time, hour Hour (BCD) 0 – 23 expression 1
Time, minute Minute (BCD) 1
Truck ID Integer 0 – 200 1
Open ID Integer 0 – 200 1
Load mass Metric ton (10-time value) 0 – 6553.5 2
Empty travel time MIN (10-time value) 0 – 6553.5 2
Empty travel distance km (10-time value) 0 – 25.5 1
Empty max. travel speed km/h 0 – 255 1
Empty ave. travel speed km/h 0 – 255 1
Empty stoppage time MIN (10-time value) 0 – 6553.5 2
Stoppage time for loading MIN (10-time value) 0 – 6553.5 2
Loaded travel time MIN (10-time value) 0 – 6553.5 2
Loaded travel distance km (10-time value) 0 – 25.5 1
Loaded max. travel speed km/h 0 – 255 1
Loaded ave. travel speed km/h 0 – 255 1
Loaded stoppage time MIN (10-time value) 0 – 6553.5 2
Dumping time MIN (10-time value) 0 – 25.5 1
Limited speed km/h 0 – 99 1
Cycle warning code 0 – FFFF (HEX) 2
Unused MIN (10-time value) 0 – 4.0 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
[BCC]: EX-OR of each bit from STX to ETX
Answer (External device VHMS controller)

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

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

(6)
• MMS communication
Transmission of unit distinction setting
After the VHMS controller is started by turning the key to the ON position, it transmits the unit distinction
setting information automatically.
Format (VHMS controller )
STX (02h) [1] [2] ETX (03h) BCC
[1]: K (ASCII) fixed

[2]: 02 (h) fixed (Unit classification [HEX])
The unit classification is the same as one used for PLM2. It is fixed to 02 (h) in the VHMS controller.
Answer ( VHMS controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or

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

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

(6)

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

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

or

Transmission of final load mass

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

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

or
10-240 HD465-7, HD605-7

(6)

Transmission of real-time data

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

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

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

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

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

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

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

bit 0: N signal1: N (OPEN) 0: Other than N (GND)
bit 1: BODY FLOAT signal 1: FLOAT (OPEN) 0: Other than FLOAT N (GND)
bit 2: Unused
bit 3: Unused
bit 4: Unused
bit 5: Unused
bit 6: Unused
bit 7: Unused
(*2) Status of dump truck [HEX]
00 (h): Engine stopped
01 (h): Empty and stopped
02 (h): Empty and traveling
03 (h): Loading
04 (h): Loaded and traveling
05 (h): Loaded and stopped
06 (h): Unloading
10-242 HD465-7, HD605-7

(6)

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

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

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

Answer (VHMS controller )

STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
HD465-7, HD605-7 10-243

(6)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

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

➀
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Model HD465-7
Engine SAA6D170E-3
Permissible
Item Measurement conditions Unit Standard value value
Power mode 2,270 ± 50 2,270 ± 50
High idling Economy mode 2,200 ± 50 2,200 ± 50
Stationary mode +0 +0
( 1) 2,100 – 100 2,100 – 100
Engine Speed Hi rpm 945 ± 50 945 ± 50

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

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

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

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

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

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

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

Blow-by pressure • Power mode kPa Max. 5.4 {550} Max. 8.8 {900}
• Torque convertor stall {mmH 2O}
(Water temperature: Operating range)

At high idling (SAE30) 0.392 – 0.539 Min. 0.206 {2.1}
{4.0 – 5.5}
At high idling (SAE10W) MPa 0.343 – 0.539 Min. 0.177 {1.8}
Oil pressure {kg/cm2} {3.5 – 5.5}
At low idling (SAE30) Min. 0.118 {1.2} Min. 0.080 {0.8}
At low idling (SAE10W) Min. 0.098 {1.0} Min. 0.069 {0.7}
Whole speed range
Oil temperature (Inside oil pan) °C 90 – 110 120
Deflection when pressed with finger

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

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

➀
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Com- Standard Permissible
ponent Item Measurement conditions Unit value value
• Engine water temperature: Standard tires Standard tires
Within operating range
F1 • Transmission oil temperature: 11.5 ± 5 % 11.5 ± 5 %
60 – 80°C
F2 • Machine unloaded 16.0 ± 5 % 16.0 ± 5 %
• Travel resistance: 3.3 %
Performance
F3 21.5 ± 5 % 21.5 ± 5 %
Travel speed F4 km/h 29.5 ± 5 % 29.5 ± 5 %
F5 39.0 ± 5 % 39.0 ± 5 %
F6 52.5 ± 5 % 52.5 ± 5 %
F7 70.0 ± 5 % 70.0 ± 5 %
R 12.0 ± 5 % 12.0 ± 5 %
Shift up • Engine water temperature: 2,100 ± 50 2,100 ± 50

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

45 – 55°C (F2 → F1 only) (F2 → F1 only)
• “Braking mode” refers to when the
Shift up 2,000 ± 50 2,000 ± 50
accelerator is OFF or the rear
Economy brake is ON. 1,300 ± 50 1,300 ± 50
mode
Shift down
1,250 ± 50 1,250 ± 50
(F2 → F1 only) (F2 → F1 only)
Shift up 2,450 ± 50 2,450 ± 50
Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
Auto lock-up
Set 1 1
Engine speed
Reset 2 2
rpm
Overrun prevention
Set 2,600 ± 10 2,600 ± 10
Reset 2,350 ± 10 2,350 ± 10
1,325 ± 35 1,325 ± 35
Down-shift inhibitor (F2 → F1 only) (F2 → F1 only)
• Transmission oil temperature:
Power
mode
85 – 110°C 1,910±100 1,910 ± 100

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

converter stall • Engine water temperature:
Economy

mode
1,910±100 1,910 ± 100
1. Min. 1,500 rpm or torque converter speed ratio is min. 0.85 at min. 1,250 rpm.
2. Min. 1,500 rpm or torque converter speed ratio is min. 0.85 at min. 1,300 rpm.
HD465-7, HD605-7 20-3

➀

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

Operating N
force {kg} 42.1 +– 7.8
2.0
42.1 –+ 7.8
2.0
Fully + 0.2 + 0.2
{4.3 – 0.8
} {4.3 – 0.8
}
Starting to • Travel at a point 150 mm from

Travel depress ↔ pedal fulcrum mm 45 ± 5 45 ± 5
fully
Operating force • At center of lever knob N 21.6 ± 3.9 Min. 29.4{3}

{kg} {2.2 ± 0.4}
Transmission shift lever
R–N
N–D
D–5
Travel mm 24.5 ± 1 24.5 ± 2
5–4
4–3
3–L
• Oil temperature: At engine speed 2,000 rpm 0.74 ± 0.05 0.74 ± 0.05
75 – 85°C {7.5 ± 0.5} {7.5 ± 0.5}
Inlet oil At high idling (2,270 rpm) 0.88 ± 0.05 0.88 ± 0.05
pressure (Reference value) {8.9 ± 0.5} {8.9 ± 0.5}
At low idling (750 rpm) 0.17 ± 0.05 0.17 ± 0.05
(Reference value) {1.7 ± 0.5} {1.7 ± 0.5}
At engine speed 2,000 rpm 0.59 ± 0.05 0.59 ± 0.05

{6.0 ± 0.5} {6.0 ± 0.5}
Outlet oil At high idling (2,270 rpm) 0.71 ± 0.05 0.71 ± 0.05
pressure (Reference value) {7.2 ± 0.5} {7.2 ± 0.5}
Torque converter
At low idling (750 rpm) 0.15 ± 0.05 0.15 ± 0.05

(Reference value) {1.5 ± 0.5} {1.5 ± 0.5}
At engine speed 2,000 rpm 1.67 ± 0.20 1.67 ± 0.20

{17 ± 2} {17 ± 2}
Lock-up oil At high idling (2,270 rpm) 1.67 ± 0.20 1.67 ± 0.20
pressure (Reference value) {17 ± 2} {17 ± 2}
At low idling (750 rpm) 1.67 ± 0.20 1.67 ± 0.20
(Reference value) MPa {17 ± 2} {17 ± 2}
{kg/cm2} 3.68 ± 0.15 3.68 ± 0.15
At engine speed 2,000 rpm
{37.5 ± 1.5} {37.5 ± 1.5}
Main relief At high idling (2,270 rpm) 3.77 ± 0.15 3.77 ± 0.15
oil pressure (Reference value) {38.5 ± 1.5} {38.5 ± 1.5}
At low idling (750 rpm) 3.33 ± 0.15 3.33 ± 0.15
(Reference value) {34 ± 1.5} {34 ± 1.5}
L, H, 3rd, • Oil temperature: 60 – 80°C 1.62 ± 0.15 1.62 ± 0.15
Control 4th clutch {16.5 ± 1.5} {16.5 ± 1.5}
valve set • Engine: at rated speed
pressure 1st, 2nd, R 3.28 ± 0.15 3.28 ± 0.15
clutch {33.5 ± 1.5} {33.5 ± 1.5}
Transmission
• Oil temperature: 0.15 ± 0.05 0.15 ± 0.05

60 – 80°C At engine speed 2,000 rpm
{1.5 ± 0.5} {1.5 ± 0.5}
(When using
EO10-CD)
Lubricating or At high idling (2,270 rpm) 0.17 ± 0.05 0.17 ± 0.05
oil pressure Oil temperature: (Reference value) {1.7 ± 0.5} {1.7 ± 0.5}
80 – 100°C
(When using At low idling (750 rpm) 0.09 ± 0.05 0.09 ± 0.05
EO30-CD) (Reference value) {0.9 ± 0.5} {0.9 ± 0.5}
20-4 HD465-7, HD605-7

➀
Com- Item Measurement conditions Unit Standard Permissible

ponent value value
• Machine unloaded
(Inflation pressure)
Standard 24.00-35-36PR 0.46 0.46

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

Parking brake
• F2
Starting test rpm Min. 1,540 Min. 1,540
• Torque converter stall
MPa
Releasing pressure See Brake {kg/cm2} See Brake
• On flat road surface 249 ± 10 249 ± 20

Front A • When empty
Installed 249 ± 10 (*1) 249 ± 20 (*1)
Suspension cylinder
mm
length 220 ± 10 220 ± 20
Rear B
204 ± 10 (*1) 204 ± 20 (*1)
Front 3.82 ± 0.39 3.82 ± 0.39

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

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

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

Turning • Engine speed: Whole range
time sec.
Right o left • Lock o lock Max. 4 Max. 5
• Oil temperature: 20.2 – 21.1 20.1 – 23.5
Steering
At high idling (2,270 rpm)

{206 – 215} {205 – 240}
valve
Relief pres- 45 – 55°C MPa

sure At low idling (750 rpm) {kg/cm2} 20.2 – 21.1 20.1 – 23.5
(Reference value) {206 – 215} {205 – 240}
• Measure at position a (Position at
150 mm from fulcrum of pedal)
Operating force (Full) N 233 ± 29.4 234 ± 29.4

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

o Full) mm 40 ± 5 40 ± 10
*1. Cylinder with buffer ring
HD465-7, HD605-7 20-5

(8)

• At point 10 mm from tip of lever N 5.9 – 9.8 3.0 – 14.7
Retarder
Operating force
control
{kg} {0.6 – 1.0} {0.3 – 1.5}

lever
Travel deg 0 0
0 – 78 –2 0 – 78 –4
• Measure at position a (Position at

150 mm from fulcrum of pedal)
Emergency brake pedall
Operating force (Full) N 296 ± 29.4 296 ± 29.4

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

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

• When first operated {180 ± 12} {180 ± 12}
Brake
actuating Rear 9.8 ± 0.7 9.8 ± 0.7
pressure (service) {100 ± 7} {100 ± 7}
MPa
Rear {kg/cm2} 8.7 ± 0.6 8.7 ± 0.6
(retarder) {88.5 ± 6.5} {88.5 ± 6.5}
• Engine: Stopped 9.85 +– 0.49
0.98
9.85 –+ 0.49
0.98
Parking brake releasing
pressure {100.4 +– 510 } {100.4 +– 510 }
• Carrying 46 ton payload

Stopping distance when • Initial speed: 32 km/h m Max. 52.1 Max. 52.1
Brakes
emergency brake is applied

• On flat, dry road surface
Operating pressure 17.6 ± 1.2 17.6 ± 1.2

at first operation after Front {180 ± 12} {180 ± 12}
accumulator is
charged MPa 9.8 ± 0.7 9.8 ± 0.7
Brake oil pressure Rear {kg/cm2} {100 ± 7} {100 ± 7}
8.7 ± 0.6 8.7 ± 0.6
Retarder {88.5 ± 6.5} {88.5 ± 6.5}
Service brake Apply the brake and set the gear shift Must not move at 1,807 rpm
lever in D and raise the engine speed
Retarder brake gradually. Measure the engine speed Must not move at 1,400 rpm
when the truck starts moving rpm
Parking brake Must not move at 1,670 rpm
Must not move until torque
Emergency brake converter stall speed
Front brake Left side 19.5 3.0

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

—
(Disc wear gauge ) Right side Must be in wear gauge range
20-6 HD465-7, HD605-7

➀
Com- Item Measurement conditions Unit Standard Permissible

ponent value value
• Engine: stopped HOLD Max. 29.4 Max. 35.3
• Center of control → RAISE {Max. 3.0} {Max. 3.6}
lever knob RAISE Must return smoothly when
→ HOLD engine is running at high idle
HOLD Max. 29.4 Max. 35.3
→ FLOAT N {Max. 3.0} {Max. 3.6}
Operating force {kg}
Dump lever
FLOAT Max. 29.4 Max. 35.3

→ HOLD {Max. 3.0} {Max. 3.6}
FLOAT Max. 29.4 Max. 35.3
→ LOWER {Max. 3.0} {Max. 3.6}
LOWER Must return smoothly when
→ FLOAT engine is running at 2,000 rpm
• Engine: stopped RAISE
→ HOLD 44.8 ± 1.9 44.8 ± 1.9
• Center of control
Travel mm
lever knob HOLD
→ LOWER 44.8 ± 1.9 44.8 ± 1.9
• Oil temperature:
Dump valve
20.1 – 21.1 19.6 – 22.6

45 – 55°C At high idle (2,270 rpm) {205 – 215} {200 – 230}
Relief pres-
sure
At low idle (750 rpm) 18.6 – 19.6 18.6 – 19.6
(Reference value) {190 – 200} {190 – 200}
MPa
Dump EPC valve
{kg/cm2} 3.4 ± 0.49 3.4 ± 0.49

At high idle (2,270 rpm) {35 ± 5} {35 ± 5}
Relief pres-
sure ( root
pressure)
At low idle (750 rpm) 2.6 ± 0.49 2.6 ± 0.49
(Reference value) {27 ± 5} {27 ± 5}
Lifting speed • Oil temperature: 45 – 55°C 11.5 ± 1.5 11.5 ± 1.5

• Engine: at rated speed sec.
Lowering speed • Use FLOAT when lowering 10.5 ± 1.5 10.5 +– 1.0
2.0
Body
• Oil temperature: 45 – 55°C

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

(9)
TESTING AND ADJUSTING
Tools for testing, adjusting, and troubleshooting ...................................................................................... 20-101-1

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

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

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

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

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

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

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

(8)
Sym-
bol
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
C 1
Fuel pump outlet pressure 1 795-799-5460 Cable 1
K 2 Commercially Tester 1
available
3 795-799-5550 Adapter 1
799-101-5002 Oil pressure gauge KIT 1

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

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

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

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

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

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

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

available
Work equipment speed R Commercially Stopwatch 1

available
Voltage, resistance S Commercially Tester 1

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

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

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

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

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

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

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

(9)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
6) Run the engine at a mid-range speed, and

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

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

(9)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED 5. After completing the adjustment, switch the

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

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

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

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

(7)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL (Measuring with measuring instruments)

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

Symbol Part No. Part Name
1 799-101-5002 Hydraulic tester
790-261-1203 Digital type hydraulic tester
C
2 Hydraulic tester
799-401-2320
(1.0MPa {10kg/cm2})
a Measure the engine oil pressure under the fol-

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

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

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

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

(9)
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY (Measuring with measuring tool)

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

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

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

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

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

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

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

(9)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
Special tool list
Digital tempera-
799-101-1502 ture gauge –99.9 – 1,299°C
B
6215-11-8170 Sensor Wire length: 490 mm
799-201-1110 Wiring harness
Wait for the temperature of the exhaust pipe to

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

(9)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5) When the temperature stabilizes at near the Method using monitoring

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

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

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

HD465-7, HD605-7 20-109

(9)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Special tool list
799-201-1504 Blow-by checker 0 – 4.9 MPa

{0 – 500 mmH2O}

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

dition.
Method using monitoring

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

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

(9)
TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF
INJECTOR
Special tool list
J 795-799-5510 Heat gun
a If the engine output drops or there is any other

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

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

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

1 795-502-1590 Compression gauge
795-611-1210 Adapter
6560-11-8410 O-ring (Top)
6560-11-8310 O-ring (2nd)
2
F 6560-11-8210 O-ring (3rd)
6560-11-8510 O-ring (4th)
6560-11-7310 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
When measuring the compression pressure, 5. Install adapter assemblies D2 to the all cylinders
take care not to burn yourself on the exhaust and secure them with the holders.
manifold, muffler, etc. or get caught in a rotat- a Install the adapter assemblies with the drain
ing part. holes in the diagonal direction of the holders.
a Secure the adapter assemblies with the
a Measure the compression pressure after the injector holders.
3 Holder mounting bolt:
engine is warmed up (Engine oil temperature: 40
– 60°C).
a Since adapter assemblies D2 of the all cylinders 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
should be removed and installed simultaneously
for efficiency, prepare 6 sets of them.
1. Open the right side cover and left side cover of

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

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

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

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

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

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

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

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

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

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

(7)
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
3) Run the engine at low idle and check that the

source voltage of the fuel pump pressure
sensor is in the following range.
a Source voltage of sensor (Between –
): 4.75 – 5.25 V
4) Run the engine at each speed in the follow-
ing table and check that the signal voltage of
the fuel pump pressure sensor is in the cor-
responding range shown in the same table.
a Signal voltage of sensor (Between –
):
Table 1 Engine speed and signal voltage
Engine Fuel pump outlet port
speed Signal voltage pressure (Reference)
1.23 ± 0.14 MPa

1,000 rpm 1.68 ± 0.21 V {12.6 ± 1.43 kg/cm2} 3) Start the engine, switch the machine monitor
to the display of "Monitoring function of ser-
1.57 ± 0.14 MPa
1,300 rpm 3.00 ± 0.21 V {16.0 ± 1.43 kg/cm2} vice mode 1", and prepare for measuring the
engine speed.
1.78 ± 0.14 MPa
1,500 rpm 3.26 ± 0.21 V {18.15 ± 1.43 kg/cm2} a For details of the method of operation, see
SPECIAL FUNCTIONS OF MACHINE
MONITOR.
2. Measuring with pressure gauge (directly)
1) Fit adapter K3 to nipple (2) for measuring the
a The engine speed is displayed in units of
pump outlet port pressure.
1 rpm.
2) Install nipple ➀ of hydraulic tester C1 to nip-
4) Run the engine at the speed shown in Table
ple (2) and connect them to hydraulic tester
1 and check that the pump outlet port pres-
H1.
sure is in the range shown in the table 1.
HD465-7, HD605-7 20-113

(9)
MEASURING FUEL PUMP INLET PORT PRESSURE (NEAGIVE PRESSURE)
TESTING AND ADJUSTING VISUAL INSPECTION OF RETURN FUEL
MEASURING FUEL PUMP 3. Run the engine at a medium speed to bleed the
oil from the hose.
INLET PORT PRESSURE a Insert the connection of the negative pres-
(NEAGIVE PRESSURE) sure gauge and hose about halfway, repeat
the action to open the self-seal portion at the
Special tool list hose end to bleed the oil.
Symbol Part No. Part Name a If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
799-101-5002 Hydraulic tester
C 1 used.
790-261-1203 Digital hydraulic tester
a If there is oil inside the hose, the gauge will
1 795-799-5550 Adapter not work, so always bleed the oil.
M Negative pressure gauge
2 795-799-5560
(0 – -0.1 MPa{0 – -1.02 kg/cm2})
4. Run the engine at full throttle and measure the
pump inlet port pressure (See Table 1).
1. Fit adapter M1 to pump inlet port pressure mea-
suring nipple (1). Table 1
2. Fit nipple ➀ of hydraulic tester C1 and hose ➁ to Fuel filter Fuel pump inlet port pressure
adapter M1 and connect them to negative pres- New Max. – 13.60 kPa {Max. – 102 mmHg}
sure gauge M2.
Used Max. – 27.10 kPa {Max. – 203 mmHg}
VISUAL INSPECTION OF
RETURN FUEL
a The fuel used for control of the timing rail in the
fuel circuit and the excessive fuel that is not used
injected in the fuel rail are returned from the
injector through the fuel cooler to the fuel tank.
a If the engine does not revolve normally or fuel
consumption is abnormally high, inspect the
return fuel according to the following procedure.
1. Disconnect the fuel return hose before the fuel

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

(9)
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
ADJUSTING INJECTOR SET a The cylinder where the injector is adjusted is

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

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

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

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

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

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

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

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

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

➀
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Crank the engine with the starting motor, push

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

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

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

➀
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST 2. Measuring with Smoke Meter G2

1) Keep the dump body raised and insert the
COLOR probe of smoke meter G2 in the joint of the
exhaust pipe and dump body and fix it to the
Special tool list exhaust pipe.
S ym bol Part No. Part Name Remarks 2) Connect the air hose and the socket of the
Handy smoke D iscoloration 0 – 70% probe hose and accelerator switch to smoke
1 799-201-9000 checker (w ith standard color)
G meter G2.
(D iscoloration x 1/10
2 795-502-1350 Smoke meter B osch index) ★ Keep the pressure of the air supply
below 1.5 MPa (15 kg/cm2).
Be careful not to touch any hot parts when 3) Connect the power cord to the AC socket.
removing or installing the measuring tools. ★ Before connecting the cord, check that
When measuring with a handy smoke meter, the power switch of the smoke meter is
avoid standing against the exhaust gas and OFF.
insert the exhaust gas suction port into the 4) Loosen the cap nut of the suction pump, and
exhaust pipe. fit the filter paper.
★ When measuring in the field where there is no air 5) Turn the power switch of smoke meter G2
or electric power supply, use handy smoke ON.
checker G1; when recording formal data, use
smoke meter G2.
1. Measuring with Handy Smoke Checker G1

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

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

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

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

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

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

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

➃
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

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

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

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

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

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

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

➀
TESTING AND ADJUSTING, AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR BELT TENSION
TESTING AND ADJUSTING,

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

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

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

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

Symbol Part No. Part Name Remarks tions and gauges to use
Pressure gauge
No. Measurement location Gauge
799-101-5002 Analog hydraulic 2.5, 5.9, 39.2, (MPa{kg/cm2})
meter 58.8 MPa {25, 60,
C1 400, 600 kg/cm2} 1 Main relief pressure 5.9{60}
Digital hydraulic Pressure gauge 2 Torque converter inlet port pressure 2.45{25}
799-401-2321 meter 58.8 MPa
{600 kg/cm2} 3 Torque converter outlet port pressure 2.45{25}
4 Torque converter lock-up clutch pressure 5.9{60}
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission 4th clutch pressure 5.9{60}
11 Transmission R clutch pressure 5.9{60}
5A- Each clutch pilot pressure 5.9{60}
11A
a The transmission lubrication temperature is rep-

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

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

sure at high idle.
4) After finishing measurement, remove the
measuring instruments and return the
removed parts.
3) Start the engine and set the gear shift lever in

the "N", and then measure the oil pressure at
low idle and high idle.
measuring instruments and return the
removed parts.
20-124 HD465-7, HD605-7

(9)
3. Measuring torque converter outlet oil pres- 4. Measuring torque converter lock-up clutch
sure and pilot pressure
1) Raise the dump body, then lock with safety
Raise the dump body and lock it with the safety
pin.
pin.
2) Remove hydraulic oil pressure measuring
Take care not to "get burned", since the oil
plug (4), (4A) and install the nipple and
temperature is high.
hoses ➀ for measurement.
When removing and installing a plug or an oil
pressure gauge, stop the engine.
1) Referring to TESTING MAIN RELIEF OIL
PRESSURE, check that there is not abnor-
mality.
{25 kg/cm2}) (including C1, ➀).
3) Lower the dump body and set to the original

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

sure at high idle.
measuring instr uments and return the
removed parts.
8) After completing the measurement, remove

the measuring equipment and set to the orig-
inal condition.
HD465-7, HD605-7 20-125

(9)
Transmission related 5. Measuring transmission Lo clutch and pilot

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

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

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

(9)
6. Measuring transmission Hi clutch and pilot 7. Measuring transmission 1st clutch and pilot
pressure pressure
1) Raise the dump body, then lock with safety 1) Raise the dump body, then lock with safety
pin. pin.
2) Remove hydraulic oil pressure measuring 2) Remove hydraulic oil pressure measuring
plug (6), (6A) and install the nipple and plug (7), (7A) and install the nipple and
hoses ➀ for the measurement. hoses ➀ for the measurement.
3) Lower the dump body and set to the original 3) Lower the dump body and set to the original
condition. condition.
4) Connect oil pressure gauge C1. 4) Connect oil pressure gauge C1.
5) Start the engine and raise the temperature of 5) Start the engine and raise the temperature of
the torque converter oil to the operating the torque converter oil to the operating
range. range.
6) Turn the parking brake switch TRAVEL, 6) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set depress the parking brake pedal, then set
the gearshift lever to position 3. the gearshift lever to position L.
7) Release the brake, travel at high idle, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idle.
cator shows "3".
In F3, a maximum travel speed of approx. 11.5 km/h is reached, so check
approx. 21.5 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe.
inal condition.

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

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

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

(9)
10. Measuring transmission 4th clutch and pilot 11. Measuring transmission R clutch and pilot
pressure pressure
pin. pin.
range. range.
the gearshift lever to position 6. the gearshift lever to position R.
7) Release the brake, travel at high idle, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idle.
cator shows "6".
In R, a maximum travel speed of
In F6, a maximum travel speed of approx. 12.0 km/h is reached, so check
approx. 52.5 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe.
inal condition.

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

(9)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
a There are 3 speed sensors installed to the trans- 3. Secure nut (3) with sensor (1).
mission. Adjust each sensor as follows.
Nut: 49.0 – 68.6Nm {5 – 7 kgm}
CN3: Input shaft speed sensor
CN4: Intermediate shaft speed sensor
CN5: Output shaft speed sensor
1. Screw in until the tip of sensor (1) contacts the

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

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

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

• Read the ACC oil pressure (front or rear)
PRESSURE when it stops rising at the highest point
(Approx. 20.6 MPa {Approx. 210 kg/
Special tool list
cm2}) after the cut-in pressure.
Pressure gauge (Measuring with diagnosing devices)
Analog hydraulic 2.5, 5.9, 39.2,
799-101-5002
meter 58.8 MPa {25, 60,
1) Stop the engine and remove plug (4) (18, P:
C1 400, 600 kg/cm2} 1.5). Connect nipple J and hose ➀ and
Pressure gauge install oil pressure gauge C1 (Oil pressure
Digital hydraulic
790-261-1203
meter
58.8 MPa gauge: 39.2 MPa {400 kg/cm2}).
{600 kg/cm2}
18 × 1.5
J 566-35-43561 Nipple
(female: PT 1/8)
Stop the machine on a level place, apply the

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

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

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

(9)
TESTING AND ADJUSTING INSPECTING BRAKE OIL PRESSURE
2. Rear brake operating pressure 4. Front brake operating pressure

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

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

➀
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE

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

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

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

➀
TESTING AND ADJUSTING TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF FRONT

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

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

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

➀
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR

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

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

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

the piston and judge the amount of wear.
★ 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.
★ Outer end b of groove D indicates the wear
limit for the disc. If it is inside guide (3) totally
[If it reaches the end face of guide (3)], the
disc has reached the wear limit.
HD465-7, HD605-7 20-135

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

★ Prepare a container to receive the oil flowing
out of the plug holes.
Tightening torque for plug:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2. Tighten the parking brake releasing bolts (M12,

Stem length: 65 – 80 mm) (2) and washers (3)
alternately and evenly to release the parking
brake.
★ Prepare bolts (2), the seats of which will
reach the washers when they are tightened
about 10 mm after their tips reach the tap
holes of parking brake piston (4).
(Length of threaded part: Approx. 23 mm)
★ Tighten bolts (2) to pull piston (4) and
release the parking brake.
20-136 HD465-7, HD605-7

➀
TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER

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

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

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

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

(8)
4. Filling suspension cylinder with gas

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

➀
5. Adjusting installed length of cylinder Note:1. Checking after changing oil and gas
★ Carry out adjustment of the installed length After the oil and gas have been changed,
of the cylinder with the machine-empty and operation of the machine causes the gas to
on level ground. dissolve in the new oil inside the cylinder
1) To remove the sliding resistance of the cylin- until it is saturated, so the volume of gas is
der (catching of bushing or packing), drive reduced and the installed length of the sus-
the machine forward approx. 15 m and stop pension goes below the specified limit.
suddenly, then drive in reverse to the original Therefore, 48 hours after changing the oil
position and stop again suddenly. Repeat and gas, check the installed length of the
this cycle 3 – 4 times, and finally, allow the suspension and adjust the gas if the length
machine to stop slowly without depressing is not within the specified value.
the brake. Then measure the installed 2. Checking for changes in installed length
length. caused by variation in ambient tempera-
★ Do not use the foot brake when braking ture.
the machine. Use the retarder control Depending on the ambient temperature
lever to brake the machine, and check when the machine is working, the gas in
that the suspension is in the soft mode. the suspension may expand or contract, so
2) If the result of the check shows that the the installed length will also change. In ter-
installed length is too long, release nitrogen ritories where there are big differences in
gas to adjust the length. temperature throughout the year, inspect
★ Loosen the oil level valve slightly to daily and adjust to keep the installed length
release the nitrogen gas. When doing within the specified range.
this, release only a small amount of gas;
do not make the cylinder move.
★ If too much nitrogen gas is released and
the cylinder moves, the installed length
may be below the specified length.
★ 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), oil level valve, and
piston rod gland.
★ Use soapy water to check for leakage of
gas.
★ If there is any leakage of gas from the
valve core, use tool [3] and remove the
valve core.
20-140 HD465-7, HD605-7

➀
TESTING AND ADJUSTING INVERTED TYPE
TESTING AND ADJUSTING REAR SUSPENSION CYLINDER
TESTING AND ADJUSTING a When releasing the nitrogen gas,

there is danger that releasing the gas
INVERTED TYPE REAR from the valve core of supply valve
SUSPENSION CYLINDER (3) will damage the valve core, so
remove the gas at the oil level valve.
a Stop the machine empty on flat ground. a When loosening the oil level valve,
loosen only the valve itself. Do not
1. Testing length of cylinder loosen the pressure sensor or nipple.
k When loosening the oil level valve,
Check that dimension "a" of the rear suspension
cylinder is within the specified value.
gradually loosen only valve (1)
Specified value for dimension "a"
itself, and do not remove the valve
: 220 ± 10 mm (Standard)
until all the nitrogen gas has been
: 204 ± 10 mm (With buffer ring)
released from the slit.
k If the nitrogen gas has not all been
Thickness Standard With buffer ring
of frange b 49 mm 65 mm
released, pressure sensor (5) are
still under high pressure, so do not
loosen them under any circum-
stances.
a When the oil level valve is loosened,
and oil and gas spurt out together,
tighten the valve slightly, and allow
time for the gas to escape slowly.
2. Releasing nitrogen gas

1) Rear suspension cylinder
i) Set block [2] between the stopper and
axle housing.
Thickness of block: 19 mm
Dimension a : 140 ± 3 mm (Standard)
: 124 ± 3 mm
(With buffer ring)
ii) Disconnect pressure sensor connector

(2) of oil level valve (1), then loosen the
oil level valve 2 – 3 turns.
HD465-7, HD605-7 20-141

(8)
3. Adjusting oil level H13 to 0.981 MPa {10kg/cm 2 } above the

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

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

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

(8)
5. Adjusting installed length of cylinder 6. Testing and adjusting dust cover

★ Carry out adjustment of the installed length ★ To protect the rear suspension from stones
of the cylinder with the machine empty and and other objects thrown up by the tires
on level ground. when the machine is traveling, carry out
1) To remove the sliding resistance of the cylin- inspection of the cover and repair or replace
der (catching of bushing or packing), drive it as necessary.
the machine forward approx. 15 m and stop 1) Check visually that there are no cracks or
suddenly, then drive the machine forward breaks in cover (1).
approx. 15 m and stop suddenly, then drive ★ If the cover is damaged, replace it with a
in reverse to the original position and stop new part.
again suddenly. Repeat this cycle 3 – 4 2) Check that hooks (2) are not missing. (3
times, and finally, allow the machine to stop places)
slowly without depressing the brake. Then ★ If any hooks are missing, remove all mud
measure the installed length. and dirt, then install hooks.
★ Do not use the foot brake when braking 3) Check that band (3) is not loose or missing.
the machine. Use the retarder control ★ If the band is loose or missing, tighten to
lever to brake, the machine, then check the following torque.
that the suspension is in the soft mode.
2) If the result of the check shows that the Band: 669 ± 49 Nm {69 ± 5 kgm}
installed length is too long, release nitrogen
gas to adjust the length.
★ Loosen the oil level valve slightly to
release the nitrogen gas. When doing
this, release only a small amount of gas;
do not make the cylinder move.
★ If too much nitrogen gas is es, the
installed length may be below the speci-
fied length.
★ 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), oil level valve, and
piston rod gland.
★ Use soapy water to check for leakage of
gas.
★ If there is any leakage of gas from the
valve core, use tool [3] and remove the
valve core.
Valve core:
16.7 – 34.3 Nm {1.7 – 3.5 kgcm}
V
a
l
v
e
c
o
r
e
:
HD465-7, HD605-7 20-143

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

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

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

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

HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
a Special tool list
Pressure gauge:
Analog hydrau- 2.5, 5.9, 39.2,
799-101-5002
lic meter 58.8 MPa {25, 60,
C1 400, 600 kg/cm2}
Digital hydrau- Pressure gauge:

790-261-1203 58.8 MPa
lic meter
{600 kg/cm2}
2. Adjusting hydraulic pressure in steering cir-

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

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

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

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

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

(9)
2. Adjusting hydraulic pressure in hoist circuit

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

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

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

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

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

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

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

➄
TESTING AND ADJUSTING AIR BLEEDING FROM STEERING CYLINDER
AIR BLEEDING FROM

STEERING CYLINDER
parking brake, then put blocks under the
wheels to prevent the vehicle from moving.
Before operating the steering wheel, be sure to

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

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

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

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

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

(9)
TESTING AND ADJUSTING PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY
PROCEDURE FOR RAISING 1) If the engine can be started, start the engine
under this condition, and the dump body
DUMP BODY IN EMERGENCY rises.
2) If the engine cannot be started, turn the
a Special tool list emergency steering switch M and raise the
dump body with the hydraulic pressure of the
emergency steering pump.
K 792T-491-1110 Plug —
a Do not operate the emergency steering
pump for more than 90 seconds continu-
a If the dump body cannot be raised because of a ously. If the load cannot be dumped in
failure in the controller or electric system, raise it 90 seconds, cool down the steering
to dump the load according to the following pro- pump, and then operate it again.
cedure.
3. Stop the engine and remove tool [K] and install
1. Stop the engine and remove the hydraulic tank plug (1).
cap to release the residual pressure from the
Tightening torque of plug:
hoist circuit.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
2. Remove plug (1) and tighten tool [K] fully.
a If tool [K] is tightened in fully, the spool is 4. When lowering the dump body, remove plug (2)
moved to the rising stroke end. and tighten tool [K] slowly.
a Distance between valve end and spool end:
103 mm. When performing this procedure, be sure
not to go under the dump body but stand
on the ground.
a The dump body lowers by itself. Keep it at

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

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

➄
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
ADJUSTING BODY 2. Adjusting link length

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

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

(8)
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
3. Calibrating system
Stop the machine on a level place and set

a Hydraulic oil temperature: 80 – 90°C
1) With the body seated perfectly, start the
engine.
2) Keep the dump control lever in the FLOAT
position for at least 5 seconds.
a Check that the FLOAT caution lamp is
turned off.
3) With the body raised to the cylinder stopper,
run the engine at low idle and keep the dump
control lever in the RAISE position for at
least 5 seconds.
4) Run the engine at high idle and raise the
body to the stroke end. Then, lower the
engine speed to low idle and set the dump
control lever in the FLOAT position to lower
the body to the seating position.
a Repeat the operations of 3) and 4) above
5 – 10 times.
5) Run the engine at high idle and raise the
body to the stroke end. Then, keep the
engine speed at high idle and set the dump
control lever in the LOWER position to lower
the body to the seating position.
a Repeat this operation 5 – 10 times.
20-151-1 HD465-7, HD605-7

(9)
METHOD FOR EMERGENCY ESCAPE WHEN
TESTING AND ADJUSTING THERE IS FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE

IN ELECTRICAL SYSTEM
If any problem occurs in the electrical system of the engine control system or transmission control system, it
may become impossible to start the engine or to move the machine off.
If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system,
move the machine to a safe place, then carry out troubleshooting.
1. When problem occurs in engine control system and engine cannot be started
a Decide the escape method according to the following flowchart.
a For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE
MONITOR.
1 2
Did [Engiine system caution NO Tow machine to safe place

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

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

YES If there is no controller to
displayed or recorded? Does engine start when en- NO
replace, tow machine to
C111KT gine controller is replaced?
safe place (see note)
C346KK (ENG)
NO
8 9
Is following service code lowing speed sensor is re- If there is no speed sensor
displayed or recorded? YES placed? NO to replace or engine does
C115KZ (ENG) Master speed sensor (SP1) not start, tow machine to
C121LC (ENG) Back-up speed sensor safe place (see note)
(SP2)
NO YES
10
Does engine start when fol- Start engine and move ma-
lowing relay is replaced? YES chine (do not turn electric
R02 (transmission neutral power ON except when ab-
relay) solutely necessary)
NO
Tow machine to safe place

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

!
2. When problem occurs in transmission control system and machine cannot be started
★ Check the service code and determine the escape method from the following chart.
★ For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE
MONITOR.
Service Condition when failure Escape method Lever position for speed range to
code occurred move off after escape operation Remarks
1380MW Occurrence condition 1 Escape procedure 1 D – L : F2, R : R

Occurrence condition 1:
1500L0 Occurrence condition 2 Escape procedure 2 — Speed range remains
15G0MW Occurrence condition 2 Escape procedure 3 D – L : F2 fixed; when the machine is
moved off again, speed
15H0MW Occurrence condition 3 Escape procedure 1 D – L : F2, R : R range does not shift.
15J0MW Occurrence condition 3 Escape procedure 1 D – L : F2, R : R ★ When lever is returned to
N, transmission shifts to
15K0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R neutral.
15L0MW Occurrence condition 2 Escape procedure 3 D – L : F1, R : R
Occurrence condition 2:
15M0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R Transmission suddenly
shifts to neutral when the
15N0MW Occurrence condition 2 Escape procedure 3 D – L : F2, R : R machine is traveling; after
15SBL1 Occurrence condition 3 Escape procedure 1 R:R machine is stopped, trans-
mission stays in neutral
15SBMA Occurrence condition 3 Escape procedure 1 D – L : F2 even when lever is oper-
15SCL1 Occurrence condition 3 Escape procedure 1 D – L : F2, R : R ated, and machine does
not move off.
15SCMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R
15SDL1 Occurrence condition 3 Escape procedure 1 D – L : F2, R : R Occurrence condition 3:
Transmission suddenly
15SDMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R shifts to neutral.
15SEL1 Occurrence condition 3 Escape procedure 1 D – L : F1 Occurrence condition 4:
15SEMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R After engine is started,
transmission stays in neu-
15SFL1 Occurrence condition 3 Escape procedure 1 D – L : F2 tral even when lever is
15SFMA Occurrence condition 3 Escape procedure 1 D – L : F1, R : R operated, and machine
does not move off.
15SGL1 Occurrence condition 3 Escape procedure 1 D – L : F4
15SGMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R Occurrence condition 5:
Response of lever
15SHL1 Occurrence condition 3 Escape procedure 1 D – L : F6 becomes abnormal; lever
does not work as operated
15SHMA Occurrence condition 3 Escape procedure 1 D – L : F2, R : R When lever is operated,
15SJL1 Occurrence condition 1 Escape procedure 1 D – L : F2, R : R transmission shifts to
neutral.
15SJMA Occurrence condition 2 Escape procedure 1 D – L : F2, R : R
Normal travel possible if display Occurrence condition 6:
D1B0KZ Occurrence condition 2 Escape procedure 4 returns to normal (Note 1) Speed range remains
fixed; when the machine is
Normal travel possible if display moved off again, speed
DAQ0KK Occurrence condition 2 Escape procedure 5 returns to normal (Note 1) range does not shift.
★ When lever is returned to
Normal travel possible if display N, transmission shifts to
DAQ2KK Occurrence condition 2 Escape procedure 4 returns to normal (Note 1)
neutral, but after that,
Normal travel possible if display transmission does not
DAQ9KM Occurrence condition 4 Escape procedure 9 returns to normal (Note 1) shift to any speed range.
Note 1:
DAQ9KQ Occurrence condition 4 Escape procedure 7 Normal travel possible if display Even when the machine
returns to normal (Note 1)
condition is restored after a
Normal travel possible if display failure, the neutral condi-
DAQAKQ Occurrence condition 4 Escape procedure 7 returns to normal (Note 1)
tion is maintained until the
DAQSMA Occurrence condition 4 Escape procedure 1 D – L : F2, R : R lever is returned to the N
position.
DDTGKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R
Note 2:
DDTHKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R This phenomenon applies
DDTJKA Occurrence condition 1 Escape procedure 1 D – L : F2, R : R when there is no display on
the machine monitor and
DDTKKA Occurrence condition 1 Escape procedure 1 D – L : F1 there is also no display in
DDTLKA Occurrence condition 1 Escape procedure 1 D – L : F2 the display window of the
transmission controller.
DDTMKA Occurrence condition 1 Escape procedure 1 D – L : F4
DDTNKA Occurrence condition 1 Escape procedure 1 R:R
DDTPKA Occurrence condition 1 Escape procedure 1 D – L : F6
HD465-7, HD605-7 20-153

➀
Service Condition when failure Escape method Lever position for speed range to
code occurred move off after escape operation Remarks
DF10KA Occurrence condition 5 Escape procedure 8 Normal travel possible if display

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

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

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

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

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

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

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

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

➄
★ All setting operations are carried out with the 1. Setting rotary switch SW1
starting switch OFF and the monitor panel Rotary switch SW1 is used to set the travel
removed. speed compensation. The machine monitor uses
★ Always set each switch and connector as the size of the standard tire to calculate the travel
instructed. speed.
★ Be careful not to touch anything inside the grom- If the tire size is changed, adjust the position of
met except for the switch. the switch to compensate for the speed display.
★ When turning the rotary switch, use a precision ★ Tire size and setting position.
cross-head screwdriver and turn slowly.
★ The protruding triangular part of the rotary switch Tire size SW1 Connector Remarks
is the setting arrow. HP465-7
24.0 – 35PR 7 Not needed
★ When changing the dipswitch, use a precision standard tire
flat-headed screwdriver and turn slowly. ★ The connector in the table indicates the num-
★ When setting, always avoid foreign matters or ber of the connector to be connected or
dust. released when changing the setting. (In the
★ After setting, be sure to install grommet. case of SW1, there is no need to connect or
release the connector.)
★ Travel speed compensation using SW1
Speed Speed
Position Position
compensation compensation
0 +7% 8 0%
1 +6% 9 –1%
2 +5% A –2%
3 +4% B –3%
4 +3% C –4%
5 +2% D –5%
6 +1% E –6%
7 0% F –7%
2. Setting rotary switch SW2

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

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

➀
3. Setting rotary switch SW3 7. Setting dipswitch SW5-4

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

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

must not be changed.
• Set position of dipswitch SW5-3: OFF
• Connector operation: Not needed
HD465-7, HD605-7 20-159

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

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TESTING AND ADJUSTING INITIAL SETTING OF PAYLOAD METER
INITIAL SETTING OF PAYLOAD METER

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

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

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

➄
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)

• EMMS: Equipment Management Monitoring System
Normal functions and the special functions of machine monitor (EMMS)

The machine monitor is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the machine monitor. The display items are divided by the inter-
nal setting of the machine monitor (EMMS), into automatic display items and items displayed when the machine
monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the operator
operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
Operator mode ↔ Service mode

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

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

➁
HD465-7, HD605-7 20-163

➁
20-163-1 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-163-2

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

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Operation and displays for operator mode

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

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

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

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

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4. Telephone number input function

The telephone number set inside the machine
monitor can be input, corrected, or canceled by
operating the switches (Fig. 5).
a When action code [E03] is displayed, the
telephone number is displayed at the same
time as [CALL].
5. Language selection function

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

a This function is applied to the "PLM in
VHMS" (Only when the option is set).
• Various functions of the "PLM in VHMS" are
displayed and set (FIG. 10).
a For details, see the operation manual for the
"PLM in VHMS".
7. Action code display function

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

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

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

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

E03 Displayed
serviceman.
8. Failure code display function

While the action code is being displayed on the
machine monitor, press the [>] button once to dis-
play the failure codes for the existing failures (Fig.
8: example).
• [>] Button: Displays failure code
a The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are recorded
as trouble data. (For details, see Service
mode.)
a If more than one failure is occurring, press
the [>] button once more to display the other
failure codes.
a After pressing the [>] button to display all the
existing failures, press the [>] button once
more to return to the service meter/odometer
display screen.
If the [>] button is pressed once more, the
failure codes will be displayed again from the
beginning.
If the switch is not operated for 10 seconds,
the display will switch automatically to the ac-
tion code screen.
a With the service code display function, the
following data are displayed (Fig. 9).
A: Failure code
(4 digits for location code + 2 digits for
problem code)
B: Controller code
(MON: Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
(BK: Retarder controller)
C: System with problem
a For details of the displayed failure codes, see
FAILURE CODE TABLE.
a With the failure code display function and
trouble data display function (Service mode),
the data that are displayed are partially differ-
ent.
a If no switch is operated on the failure code
display screen for more than 30 seconds, the
display automatically returns to the action
code display screen.
HD465-7, HD605-7 20-167

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FAILURE CODES LIST

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

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

➄

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

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

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

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

➄

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

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

➄

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

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

➄

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

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

➄

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

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

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

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

These failure codes are not recorded as trouble data for either the electrical system or the mechanical sys-
tem.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the trou-
bleshooting section are linked, so check the controller code for the failure code displayed, then go to the ap-
plicable troubleshooting mode.
ENG: Troubleshooting of engine controller system (ENG MODE)
TM: Troubleshooting of transmission controller system (TM MODE)
BK: Troubleshooting of retarder controller system (BK MODE)
MON: Troubleshooting of machine monitor system (MON MODE)
VHMS: Troubleshooting for VHMS controller system (including payload meter system in VHMS)
(VHMS mode)
20-174 HD465-7, HD605-7

➄
Procedure for switching to Service mode and

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

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

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

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

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

(9)
5) Menu selection in Service mode

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

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

(9)
9. Electrical system trouble data display func-

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

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

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

(9)
4) Switching trouble data display

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

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

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

➀
10. Mechanical system trouble data display func-

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

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

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

(9)
4) Switching trouble data display

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

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

➀
11. Machine data monitoring function (REAL-

TIME MONITOR)
The machine monitor can monitor the condition
of the machine in real time through the signals
from the sensors installed to various parts of the
machine.
In the machine data monitoring function, the fol-
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
on the menu screen of Service mode (Fig. 1).
2) Display sub menu

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

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

(9)
4) Setting 1st item individual monitoring

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

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

➀
6) Setting 2nd item simultaneous monitoring

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

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

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

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

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

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

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

➀
TRANSMISSION (Transmission controller system)

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

➀

code
33 Fill time of 2nd clutch FILL TIME 2 41803 0 – 2550 ms
34 Fill time of 3rd clutch FILL TIME 3 41804 0 – 2550 ms
35 Fill time of 4th clutch FILL TIME 4 41805 0 – 2550 ms
36 Fill status of Hi clutch FILL H 31501 0–2 Status display
37 Fill status of Lo clutch FILL L 31500 0–2 Status display
38 Fill status of R clutch FILL R 31506 0–2 Status display
39 Fill status of 1st clutch FILL 1 31502 0–2 Status display
40 Fill status of 2nd clutch FILL 2 31503 0–2 Status display
41 Fill status of 3rd clutch FILL 3 31504 0–2 Status display
42 Fill status of 4th clutch FILL 4 31505 0–2 Status display
43 Input voltage of acceleration sensor THROTTLE POS 31700 0.00 – 5.10 V
44 Operation status of emergency steering (1 & 2) ENERG STRG 1,2 32100 ON/OFF, ON/OFF Status display
45 Input status of alternator terminal R ALTERNATOR R 04301 ON/OFF Status display
46 Input status of starting switch terminal C KEY SW C 32300 ON/OFF Status display
47 Setting status of emergency escape switch ENERG TRAVEL 32400 ON/OFF Status display
48 ECMV oil temperature ECMV OIL TEMP 32500 0 – 160 °C
49 Torque converter oil pressure T/C OIL PRESS 32600 0.00 – 5.02 MPa
50 Steering oil temperature OVERHEAT/NOR- Status display

STRG OIL TEMP 32700 MAL
51 Output status of overrun prevention brake OVERRUN BK DIR 35001 ON/OFF Status display
52 Output status of DROOP MODE 2 (P/E) DROOP MODE 2 38100 ON/OFF Status display
53 Connector check input status (1 & 2) CONN CHK 1,2 30701 ON/OFF, ON/OFF Status display
54 Hydraulic tank level HYD OIL LEVEL 33000 LOW/NORMAL Status display
55 Engine oil tank level ENG OIL LEVEL 38200 LOW/NORMAL Status display
56 Transmission oil tank level TM OIL LEVEL 38300 LOW/NORMAL Status display
57 Electrolyte level BATT LIQ LEVEL 40302 LOW/NORMAL Status display
58 Radiator water level COOLANT LEVEL 33100 LOW/NORMAL Status display

CLOGGED/NOR-
59 Clogging status of air cleaner AIR CLEANER 33200 MAL
Status display
60 Clogging status of transmission filter CLOGGED/NOR- Status display

T/M FILTER 33300 MAL
61 Clogging status of hydraulic oil filter CLOGGED/NOR- Status display
HYD OIL FILTER 33400 MAL
CLOGGED/NOR-
62 Clogging status of engine oil filter ENG OIL FILTER 38400 MAL
Status display
63 Judgment of acceleration at gear shifting point ACCELERATON 38500 QUICK/NRMAL Status display
64 Holding status of skip-shift TM SKIP SHIFT 38600 KEEP/NORMAL Status display
65 Gear shift mode status TM SHIFT MODE 38700 0–F Status display
20-186 HD465-7, HD605-7

➀

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

➀
ENGINE (Engine controller system)

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

➀
BRAKE (Retarder controller system)

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

➁
BRAKE [Retarder controller system]

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

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

➄
VHMS (VHMS controller system)

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

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

➁
12. Adjustment function (TUNING)

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

chine monitor and machine itself, and carry out
the following items in order (Fig. 2).
a ( ) indicates the menu to use for the adjust-
ment operation.
(1) Adjusting individual difference of valve (02:
ECMV TUNING AUTO)
(2) Resetting gearshifting feeling stabilized
learning data (01: TM TRIGGER)
(3) Gearshifting feeling stabilized initial learning
(monitoring function)
a The MANUAL menu of [02: ECMV TUNING]
is a special function for the factory and is not
used for service.
HD465-7, HD605-7 20-191

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

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

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

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

(9)
Adjustment operation (1): Adjusting individual

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

(7)
Adjustment operation (2): Resetting gearshifting

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

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

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

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

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

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

(9)
4) Set the gearshift lever in the 6 position. Run the

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

(7)

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

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

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

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

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

item
i) With the menu selected, press the [ ]
button and display the initial screen of
the set item (Fig. 2).
ii) Press the [>] or [<] buttons to select the
item to be set.
• [>] button: Goes on to next item
• [<] button: Goes back to last item
a The set items are displayed endlessly in
the internal set order (for details, see Ta-
ble of filter and oil replacement time set
items).
3) If the maintenance items in the display for

the filter and oil replacement time set items
are selected, the following content is dis-
played (Fig. 3).
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
3: Number of times of replacement up to
present
4) Changing replacement interval

i) With the set items selected, press the
[ ] button and display the interval input
screen (Fig. 4: example).
• [ ] button: Executes change func-
tion
★ The presently set interval is dis-
played on the screen.
20-196 HD465-7, HD605-7

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

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

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

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

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

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

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

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

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

• [t] button: Stop inputting number.
0.158 miles).
If the set value is too small, the system
may recognize that loading is completed
while the dump truck is still being load-
ed.
2) Correction of calculation of payload
Since this function affects the accuracy
directly, execute the following procedure
securely.
Be sure to measure the weight of the
empty dump truck and that of the fully
loaded dump truck "as a set" according
to the following procedure.
The dump truck must travel for about 3
minutes each after the weight of the
empty dump truck and that of the fully
loaded dump truck are measured. Ac-
cordingly, secure a road for this pur-
pose.
20-197-1 HD465-7, HD605-7

➄
The relationship between the suspen-

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

ous screen.
truck has been input and the

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

value.
on the right side of WEIGHT.

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

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

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

➄
(3) Input the measured weight of the

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

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

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

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

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

➄
(6) Display the progress of measure-

ment (Fig. 9).
• [t] button: Stop measurement
a n d r e t u r n t o th e p r e v i o u s
screen.
a As measurement is executed,
the number of " * " increases.
When measurement is finished,
the next screen appears auto-
matically.
iii) Load the dump truck to measure the
weight of the fully loaded dump truck
(Fig. 10).
• [t] button: Return to the menu
screen.
a When loading is started, the menu
s cr een app ears automati cal ly.
When indicating the current load for
reference while the dump truck is be-
ing loaded, go out of "Service mode"
temporarily and return to "Display of
load/integrated odometer". On this
screen, you can check the current
load.
iv) Measure the weight of the fully loaded
dump truck with the load meter and
record it (Write it on a sheet of paper,
etc.)
v) Input the measured weight of the fully
loaded dump truck and drive the dump
truck for about 3 minutes.
(1) Select "LOADED WEIGHT" (Fig.
11).
a For the method of displaying the
following screen, see the steps
up to ii) - (1).
• [>], [<] buttons:
Select "EMPTY WEIGHT" or
"LOADED WEIGHT".
• [U] button: Enter the selection.
• [t] button: Return to the previous
screen.
a If the weight of the empty dump
truck has been input and the
dump truck has been driven for
about 3 minutes, "LOADED
WEIGHT" is displayed when the
menu is selected (See Fig. 11).
• Check the unit of the input
value.
a The unit is indicated in the ( )
on the right side of WEIGHT.
HD465-7, HD605-7 20-197-4

(9)
(2) Check that measurement of the

weight of the fully loaded dump truck
has been completed.
• [U] button: Check that measure-
ment has been completed and
go to the next step.
ous screen.
(3) Input the measured weight of the ful-

ly loaded dump truck (Fig. 6).
• [>] button: Number at cursor
moves forward.
• [<] button: Number at cursor
moves backward.
• [U] button: Enter number at cur-
sor.
• [t] button: Return to the largest
position of the number to input
the value again. If this button is
pressed again, inputting of the
value is stopped and the previ-
ous screen appears.
a Inputtable range
HD465-7:
However,
A1 = {43.6 [t] (Operating weight)
+ 46 [t] (Load capacity)}
HD605-7:
However,
A2 = {46.8 [t] (Operating weight)
+ 63 [t] (Load capacity)}
(4) Check the input value (Fig. 7).
20-197-5 HD465-7, HD605-7

➄
(5) Move the dump truck to a place

where you can drive it.
• [U] button: After getting ready

for drive, press this button and
a Drive the dump truck for about 3

start driving the dump truck.
minutes (at a speed higher than

8 km/h) to enter the relationship
between the weight of the dump
truck and the suspension pres-
sure under that weight.
• [t] button: Return to the screen
for inputting values.
(6) Display the progress of measure-
ment (Fig. 9).
• [t] button: Stop measurement
a n d r e t u r n t o th e p r e v i o u s
a As measurement is executed,
screen.
the number of " * " increases.

When measurement is finished,
the next screen appears auto-
matically.
vi) Dump the load in the dump area (Fig.
12).
a If the load is dumped with the dump

screen.
lever, the menu screen appears au-

tomatically.
If the load is dumped normally, cor-
rection is finished.
3) Correction of level of inclination sensor
i) Move the dump truck to a level place.
ii) Input the clinometer reading (F) at the
current position and that (R) after turning
180 degrees (stopping it in the opposite
direction) on the same position and use
the average value as the standard level.
(1) Enter value of (F) (Fig. 13).
• [U] button: Enter the flashing
value.
a The current standard level value

screen.
is displayed on the upper line.

The clinometer value (F) at the
current position flashes. Enter it
when it is stabilized.
HD465-7, HD605-7 20-197-6

➄
(2) Turn the dump truck 180 degrees

(Stop it in the opposite direction).
(3) Enter value of (R).
• [U] button: Enter the flashing
value.
a The current standard level value

screen.
is displayed on the upper line.

The clinometer value at the cur-
rent position flashes. Enter it
when it is stabilized.
(4) Enter the standard level value (Fig.

15).
4) Setting of criterion of maximum travel speed

Input a criterion of the maximum travel speed
by pressing the following buttons (Fig. 16).
ward.
ward.
a The setting range is 0 – 99 km/h (0 – 62

MPH). (Default: 99 km/h)
5) Setting of payload to recognize start of load-

ing
Input a payload to recognize start of loading
by pressing the following buttons (Fig. 17).
ward.
ward.
a The setting range is 0 – 25.5%.

(Default: 15%)
This function does not assure the opera-
tion because of the contrary phenomena
shown below (on the next page).
20-197-7 HD465-7, HD605-7

➄
• If the value is reduced, start of loading

may be recognized wrongly.
• If the value is increased and a loader
having a small-capacity bucket is used,
the forecast function of the outside indi-
cator lamps and the MMS communica-
tion may not operate normally.
6) Setting of indication range of outside indica-
tor lamps
Input an indication range of the outside indi-
cator lamps by pressing the following buttons
(Fig. 19).
ward.
ward.
a The setting range is 0 – 130% of the load

capacity.
Set A (Yellow lamp) higher than G (Green
lamp) and set R (Red lamp) higher than A
(Yellow lamp), however.
7) Setting of OFFSET function
Input an offset range by pressing the follow-
ing buttons (Fig. 20).
ward.
ward.
a The setting range is -5.0 – +5.0 [t].

• Check the unit of the input value on
a The unit is indicated in the ( ) on

the previous menu screen (Fig. 21).
the right side of the input value

[t].
HD465-7, HD605-7 20-197-8

➄
8) Selection of method of entering saved pay-

load
i) Select the method of entering the saved
payload (Fig. 22).
• [>], [<] buttons: Select "WHEN
DUMPING" or "WHEN TRAVEL-
ING".
• WHEN DUMPING (Setting at
time of shipment)
The payload measured when
the dump lever is shifted from
the "FLOAT" position to "another
position" in the dump area is
saved.
• WHEN TRAVELING
The data sampled while travel-
ing from the loading area to the
dump area is processed statisti-
cally and the hauled payload is
entered and saved when it is
dumped.
• [U] button: Enter the selected meth-
od.
screen.
ii) Enter the selected method (Fig. 23).
16. Initialize function (INITIALIZE)

(exclusive function for factory)
★ This is a special function for the factory and
is not used for service.
20-198 HD465-7, HD605-7

➄
TESTING AND ADJUSTING BASIC PRECAUTIONS
BASIC PRECAUTIONS that is connected directly to the battery

and always supplies electricity (perma-
1. Handling machine, safety, inspection and nent power source) in addition to the
maintenance power source (switch power source) that
For details of safety items, operation, inspection, is cut when the starting switch is turned
and maintenance of the machine, see the Opera- OFF or the engine is stopped.
tion and Maintenance Manual for the machine. Because this switch power source and per-
manent power source are provided, the
2. Handling monitoring system period needed for collecting data is clearly
Always obey the following precautions when known and it becomes possible to store this
handling the monitoring system. data in the internal memory.
1) When disassembling, repairing, or modifying In other words, the VHMS uses the perma-
the machine or system, follow the instruc- nent power source to save to memory the
tions in the manual. data accumulated from the moment the start-
2) Do not touch the system (equipment) when ing switch is turned ON to the moment the
operating the machine. starting switch is turned OFF. Then the
3) Do not damage or get the wiring harnesses, VHMS controller itself turns off the perma-
connectors, or sensors of the system (equip- nent power source.
ment) caught or pulled by force. This may 2) Precautions when turning the permanent
cause short circuits or disconnections that power source OFF
will lead to failure or fire on the machine or When the starting switch is turned OFF, the
system (equipment). power supply is maintained for at least 3 min-
4) Do not get water, dirt, or oil on the system utes (the VHMS system shut-down time: the
(equipment). time taken for the VHMS system to save the
data to memory and switch off), and then the
3. Permanent power source for VHMS (battery permanent power source is turned OFF.
direct power source) If the VHMS system shut-down time is
1) Meaning and need of permanent power shorter than 3 minutes, the accumulated
source data may be damaged.
The VHMS has the function of checking and a. When removing VHMS from permanent
collecting data on the condition of the machine power source
from the moment the starting switch is turned When removing the VHMS from the per-
ON to the moment the starting switch is turned manent power source (for example,
OFF. Therefore, its power supply is different- when carrying out repairs), check that
from many of the electronic equipment and the monitor display (7-segment LED in
electrical parts. the diagram below) of the VHMS control-
For the system to provide the above func- ler is out.
tions, it is necessary to have a power supply
20-203-1 HD465-7, HD605-7

➁
b. When installing battery isolator or other

battery shut-down device
i) Basic connections
It is a basic assumption that the
engine stop switch is a type that will
not shut off the permanent power
source when the engine is stopped.
ii) When safety regulations for user
make it impossible to avoid shutting
down all electric power
• Install a battery isolator so that
the permanent power source is
kept in the specified condition for
at least 3 minutes after the start-
ing switch is turned OFF before
the permanent power source is
shut down.
• If there is no timer, wait for at
least 3 minutes before turning off
the permanent power source.
• If the above shut-down time is
shorter than 3 minutes, the accu-
mulated data may be damaged.
4. Precautions when VHMS power source is ON

• For the first few seconds after the power is
switched ON, the VHMS controller carries
out the initial check (LEDs flash). Do not
carry out any of the following operations until
the initial check is completed.
• Operation of manual snapshot switch
• Downloading from PC
(Check that the LEDs are displaying the
aggregate numerals in turn before oper-
ating.)
5. Precautions when replacing VHMS and trans-

mission controller
1) Before starting replacement
a. Download VHMS data b. Specified method of shutting down
When the VHMS controller is replaced, VHMS power source
the data collected up to that point is lost, i) Use the starting switch to turn the
so be sure to download the accumulated normal power source OFF
data before starting the replacement ii) Maintain the permanent power
operation. source in the specified condition
Next, send the accumulated data to web for at least 3 minutes.
care. iii) Turn the permanent power source
For details of the method of download- (battery direct) OFF.
ing, see the separate instruction manual
for the technical analysis tool box.
HD465-7, HD605-7 20-203-2

(9)
2) Method of replacement, action after

replacement
When replacing the VHMS controller, be
careful not to subject the VHMS controller or
wiring harnesses to any excessive force or
impact, and carry out the initial setup. For
details, see the separate instruction manual
for the technical analysis tool box.
6. Handling communications controller (ORB

• • • Orbcomm)
1) The ORB controller must be used. If the
ORB controller is not used, it is impossible to
carry out the request to open communica-
tions before starting to use.
If the control power is turned on before com-
pleting the request, the transmission will be
unauthorized and there will be problems with
the communications system.
If there are any problems or any part is
unclear, please contact Komatsu or the per-
son responsible for operation.
2) Finally, turn on the ORB power ON (connect
the connector). After the VHMS controller
confirmation is completed, connect the ORB
controller connector (ORB-A, ORB-B).
20-203-3 HD465-7, HD605-7

➁
TESTING AND ADJUSTING OUTLINE
OUTLINE
★ It is also possible to add this system to a machine that has already been shipped.
1. Basic structure (1)
HD465-7, HD605-7 20-203-4

➁
2. Basic structure (2)
20-203-5 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-203-6

➁
3. Position of equipment
Install monitoring controller (VHMS controller) (1)
on the machine, and collect the operation data
for the engine, transmission, and PLM.
1) Data collection function
i) Data from connected sensors
• Blow-by pressure {sensor (2)}
• Engine oil temperature {sensor (3)}
• Exhaust gas temperature {sensor (4)}
• Ambient temperature {sensor (5)}
ii) Data from controller mounted on machine
• Engine speed
• Fuel injection amount
• Engine oil pressure
• Data from transmission controller
• Data from retarder controller
• Data from PLM II controller
• SMR (service meter)
2) Saving data
• The above data is saved to memory.
20-203-7 HD465-7, HD605-7

➁
3) External communication function

• Connect the PC (personal computer) to
the VHMS controller, download the data,
and transmit the data through the Inter-
net.
• Send the data automatically from remote
areas through the communications satel-
lite (ORB).
(6): Ground level download connector
(7): Download connector inside cab
(8): Communications antenna/pole
Antenna mount:
Thread tightener (LT-2)
HD465-7, HD605-7 20-203-8

➁
TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER
SETTING UP VHMS 2. Setting items

• VHMS: For details of the setup method, see
CONTROLLER the instruction manual for the technical anal-
ysis tool box (for service).
1. Setting up VHMS controller 1) Calendar (data, time, time difference
• In the following cases, always carry out the from GMT, summer time (daylight saving
setup. time))
1) When making the initial installation of the 2) Machine model, Serial No., variation
VHMS system code
2) When replacing or overhauling the fol- 3) Engine model, Serial No.
lowing components 4) Transmission Serial No.
• VHMS controller • For details of the method of setting PLM II
• Engine and VHMS with PLM function, see the sepa-
• Transmission rate PLM instruction manual.
• PLM II (option) 1) Time of the start of data collection
• When carrying out the setup, the following 2) Data collection unit (day)
are needed • Opening communications with Orbcomm:
1) PC (personal computer) For details of the setup method, see the
2) VHMS analysis tool (software) instruction manual for the technical analysis
(799-608-3211) tool box (for service).
3) Download cable (799-608-3220) 1) Communications method (stop/start, inter-
• For details of the setup method, see val, transmission time)
the instruction manual for the techni- 2) Time of PLM data collection
cal analysis tool box (for service). 3) Country code for communications con-
• The setup operation is carried out by troller (GCC)
trained personnel under the guidance
of the person responsible at your
company.
• Or contact Komatsu.
3. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON (starting switch ON) Check that no error is generated by the VHMS controller or other
1 • Check for generation of errors controller
• Start setup tool If there is any error, repair or correct to return condition to normal
• Calendar (data, time, time difference from GMT, summer time
(daylight saving time))
2 Setting up VHMS • Machine model, Serial No., variation code
• Engine model, Serial No.
• Transmission Serial No.
Setting up PLM function or PLM II (when the • Time of start of data collection
3 PLM function is available or machine is PLM II
specification) • Data collection unit (day)
4 Starting switch OFF (starting switch OFF) • Saving settings
5 Starting switch ON (starting switch ON) • Checking VHMS functions

Start engine • Performing test (quick PM)
6 Test (quick PM) • Downloading
Starting switch OFF • Checking data (content of data)
Starting switch ON (starting switch ON) • Checking operation of Orbcomm
7 • Check for errors • Setting up communications
• Start setup tool (need for communications file, communications frequency, GCC
code)
8 Starting switch OFF (starting switch OFF)

• Setup completion report, content of setup (data), sending checksheet
• Sending download data
20-203-9 HD465-7, HD605-7

➁
TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER
4. Checking operation, actuation

★ Check the functions of the VHMS system as follows.
Start
Turn starting switch to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Abnormality in machine syastem Possible abnormality in VHMS cont-

See machine shop manual roller
5. Collection of data
★ If there is no abnormality in the system, the machine will operate and the operation data for the machine
will automatically be saved by the VHMS controller.
HD465-7, HD605-7 20-203-10

➁
TESTING AND ADJUSTING COLLECTION, TRANSMISSION OF DATA
COLLECTION, TRANSMISSION OF DATA

1. Collection of data
1) Downloading with PC (personal computer) ★ For details of downloading and sending
<Necessary tools> the data, see the instruction manual for
• PC (personal computer) the technical analysis tool box (for ser-
• VHMS analysis tool (software) vice).
(799-608-3211) 2) Automatic transmission by communications
• Download cable (799-608-3220) satellite (machines with Orbcomm specifica-
When using a PC to download the collected tion)
data, send the data to the file server in the • Error data and other specified data are
computer center by e-mail (Internet). automatically sent by communications
(There are limitations to the capacity of satel- satellite to the file server in the computer
lite communications, so use this method to center.
send all the data.)
2. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON (starting

switch ON) Check that no error is generated by VHMS controller or other controller
1 • Check for generation of errors If there is any error, repair or correct to return condition to normal
• Start setup tool
• Checking satellite communications data, setting communications fre-
2 Setting up communications quency
• Setting GCC code
3 Starting switch OFF (turn key to OFF) • Saving set values

• Reporting completion of setup
3. Carrying out quick PM

★ For details, see TESTING AND ADJUSTING,
Performing PM clinic using manual snap-
shot.
• To collect data under the normal working
conditions, and to collect data when operat-
ing under such conditions as torque con-
verter stall or high idling, carry out the quick
PM (equivalent to PM clinic) before down-
loading with the PC.
4. Method of downloading with PC (personal

computer)
To ensure safety, stop the machine on flat
ground and put blocks under the tires to
prevent the machine from moving.
When turning the starting switch ON, check
that the parking brake is ON and that the
gearshift lever is at the N position.
Sound the horn to warn people in the sur-
rounding area before starting the engine.
★ For details of the method of using the PC,
see the instruction manual for the technical
analysis tool box (for service).
<Preparatory work>
• Prepare a PC for downloading and a download
wiring harness.
★ The download connectors are provided in 2
places: rear of assistant's seat inside cab (7) and
behind front left tire of machine (6).
20-203-11 HD465-7, HD605-7

➁
<Downloading from connector inside cab> <Downloading from ground level connector>
1) Remove the connected wiring harness and install 1) Remove the clamp at the top of the download
the download cable. box.
2) Connect the other end of the download wiring 2) Use the engine key to open the cover at the front
harness to the PC. of the box.
3) Turn the machine starting switch ON, check that 3) Remove the cap of the download connector and
the monitor controller is working, then download install the download cable.
to the PC. 4) When turn (wake-up) switch (10) is turned, the
★ To check that the VHMS controller is working, VHMS is actuated and pilot lamp (11) lights up.
check that the VHMS controller starts up, 5) Check that pilot lamp (11) is lighted up, then
LEDs flash (see diagram below), and aggre- carry out the PC download.
gate numerals are displayed in order. 6) When [complete] is displayed on the download
4) When [complete] is displayed on the download PC, the download operation is completed.
PC, the download operation is completed. 7) Return the turn switch to its original position,
5) Turn the machine starting switch OFF, then turn remove the download cable, then install the cap.
the PC power OFF, remove the download cable, 8) Check that pilot lamp (11) is out, then close the
and return the wiring harness to its original condi- box cover.
tion. If the turn switch is not off, the cover will not
close.
9) Turn the engine key and lock the front cover.
Close the clamps at the top of the box also.
4. Types of data collection files

1) Index file : This records the common data for the machine model, serial No., and service meter
(SMR).
2) VHMS history : This records changes in the VHMS.
3) Machine history : This records the actual engine operation data.
4) Fault history : This records errors that occurred in order of occurrence.
5) Trend analysis : This records the maximum or minimum values for each measurement device at the
specified intervals. (See Table 1)
6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures.
(see Table 2)
7) Snapshot : This records the data for a specified time before and after the occurrence of an error
(see Table 3.1, 2)
8) Load map : This records the frequency of the applicable area, taking the engine speed and fuel
injection amount as the axes
9) Cycle interval : This records the aggregate frequency of the changes in engine speed
10) Running area : This records the operation distribution for each area on the engine performance
graph
11) Running direction : This records the track of movement for each area on the engine performance graph
12) Transmission shift change map: This records the transmission gearshift data
13) Transmission fill time trend : This records the transmission clutch engagement time data (See table 4)
14) Payload data (option) : This records the payload meter data
15) Payload data cycle (option) : This records the operating cycle data for the machine
HD465-7, HD605-7 20-203-12

➁
TREND DATA ITEMS
Table 1: Trend analysis data

No. Item Content Unit Data collection point Remarks
1 SMR Service meter h
2 Calendar Calendar y/m/d h:m:s
3 Engine speed max. Engine speed (max) rpm Engine controller Maximum value within set trend data
Crankcase internal
4 Blow-by press. max. Blow-by pressure (max) mmAg (Every 20 hours) See as below
pressure sensor
Exhaust temperature
5 F. Exh. temp. max. Front engine exhaust temperture (max) deg C
sensor
Exhaust temperature
6 R. Exh. temp. max. Rear engine exhaust temperture (max) deg C sensor
7 E. oil press. max. Engine oil pressure (max) kg/cm2 Engine controller
8 E. oil P. L min. Engine oil pressure at low idling (min) kg/cm2 Engine controller
9 E. oil P. H min. Engine oil pressure at high idling (min) kg/cm2 Engine controller
Engine oil temperature
10 Eng. oil temp. max. Engine oil temperature (max) deg C sensor
11 Fuel rate Fuel consumption rate (average) Liter/h Engine controller
12 Cool temp. max. Engine coolant temperature (max) deg C Engine controller
13 Cool temp. min. Engine coolant temperature (min) deg C Engine controller
Engine controller (ambi-
14 Ambient temp. max. Ambient temperature (max) deg C
ent temperature sensor)
15 Ambient temp. ave. Ambient temperature (average) deg C ent temperature sensor)
16 Ambient temp. min. Ambient temperature (min) deg C
17 Atmos. press. ave. Atmospheric pressure (average) hPa Engine controller
18 F. brake P. max. Front brake oil pressure (max) 2 Retarder controller

kg/cm
19 R. brake P. max. Rear brake oil pressure (max) kg/cm2 Retarder controller
Table 2: Machine trend data


T/C oil temp. 120– Time of use for each torque converter
3 T/C oil temp. 130– Transmission controller
oil temperature
T/C oil temp. 140–
sec.
Rtrdr. oil temp. T120– Time of use for each retarder oil tem-
4 Rtrdr. oil temp. T130– Retarder controller
perature
Rtrdr. oil temp. T140–
Table 3.1 Observation items (trigger items) for auto snapshot

No. Content Failure code No. Content Failure code
No. 1,2,3 cylinder exhaust temperature is high 11 Problem with No. 2 clutch 15L0MW(b025)
1 (stage 1) F@BYNS(M361)
No. 4,5,6 cylinder exhaust temperature is high 12 Problem with No. 3 clutch 15M0MW(b026)
2 (stage 1) F@BZNS(M371)
3 Blow-by pressure is high F@BBZL(M338) 13 Problem with No. 4 clutch 15N0MW(b027)

No. 1,2,3 cylinder exhaust temperature is high 14 Problem with R clutch C115KZ
4 (stage 2) F@BYNR(M362)
No. 4,5,6 cylinder exhaust temperature is high 15 Problem with M clutch C151NS
5 (stage 2) F@BZNR(M362)
6 Double meshing of transmission clutch 1500L0(b005) 16 Abnormality in torque converter output signal C261NS
7 Problem with lock-up clutch 1380MW(b021) 17 Overheating of torque converter B@CENS(A0d2)
8 Problem with High clutch 15H0MW(b022) 18 Overheating of rear brake oil B@C7NS(A0d4)
9 Problem with Low clutch 15J0MW(b023) 19 Overrun A00N1(M201)
10 Problem with No. 1 clutch 15K0MW(b024) 20 Abnormal drop in engine oil pressure C143ZG
20-203-13 HD465-7, HD605-7

➄
Table 3.2 Data items for manual snapshot

1 Time Elapsed time sec. VHMS
2 Eng. speed Engine speed rpm Engine controller
3 Fuel inject Fuel injection amount mm3/st Engine controller
4 Blow-by press. Blow-by pressure mmAg Crankcase internal

pressure sensor
Exhaust temperature (No. 1,2,3 cylin- Exhaust temperature
5 F. exh. temp. deg C sensor
ders)
Exhaust temperature (No. 4,5,6 cylin- Exhaust temperature
6 R. exh. temp. deg C
ders) sensor
7 Eng. oil. press. Engine oil pressure kg/cm2 Engine controller
8 Eng. oil. temp. Engine oil temperature deg C Oil temperature sensor
9 Eng. cool. temp. Engine coolant temperature deg C Engine controller

10 Ambient temp. Ambient temperature deg C
11 Boost press. Engine boost pressure mmHg Engine controller
12 Accelerator pos. Accelerator angle % Engine controller

FLOAT = 0, HOLD = 1, LOWER = 2,
13 Hoist lev. pos. Hoist lever position — Retarder controller RAISE = 3, Max height = 4, Other = 5
14 T/C oil temp. Torque converter oil temperature deg C Transmission controller
15 T/M out. speed Transmission output speed rpm Transmission output

shaft speed sensor
16 Shift indicator Gearshift range (position) — Transmission controller R = 10, N = 0, F1 = 1, ••• F7= 7
17 Lockup signal Lock-up clutch ON-OFF Transmission controller
18 Retarder temp. Retarder oil temperature deg C Retarder controller
19 F. brake press. Front brake oil pressure kg/cm2 Retarder controller
20 R. brake press. Rear brake oil pressure kg/cm2 Retarder controller
21 Retarder position Retarder brake use ON-OFF Retarder controller
22 Foot brake position Foot brake use ON-OFF Retarder controller
Table 4: Transmission trend data


Trig. time Low
(fill time)
Trig. time High
(fill time)
Trig. time Rev.
(fill time)
Trig. time 4th
3 (fill time) Transmission fill-up time msec. Transmission controller (Every 200 h)
Trig. time 3rd
(fill time)
Trig. time 1st
(fill time)
Trig. time 2nd
(fill time)
HD465-7, HD605-7 20-203-14

➁
5. Confirming data <Checking quick PM data>

For details of the method of confirming the data, • Engine speed (high idle, torque converter stall)
see the instruction manual for the technical anal- • Blow-by pressure (high idle, torque converter
ysis tool box. stall)
★ Check that each file has been saved. Check • Exhaust temperature (torque converter stall)
also that there is no abnormal data. • Engine oil pressure (low idle, high idle, torque
★ Compare the quick PM data and the PM converter stall)
clinic data to check that there are no abnor- • Engine oil temperature (no PM data ••• reference
mal values. value)
★ After downloading, if there is no problem with
the data, clear only the snapshot data.
For details of the method of clearing, see the
instruction manual for the technical analysis
tool box (for service).
20-203-15 HD465-7, HD605-7

(9)
TESTING AND ADJUSTING INSPECTION AND MAINTENANCE, REPLACING PARTS
INSPECTION AND REPLACING PARTS

MAINTENANCE If initial setup of VHMS system has been made or
1. Inspection interval: Inspection and mainte- VHMS controller has been replaced
nance interval for machine If the system has been newly installed or the VHMS
Check the system at the same time as carrying controller or other components (transmission, engine,
out maintenance on the machine. etc.) have been replaced, it is necessary to carry out
the initial setup of the system.
2. Inspection items • Necessary tools
★ Carry out inspection and maintenance, and 1) PC (personal computer)
take the necessary action if there are any 2) VHMS analysis tool (software)
abnormalities. (799-608-3211)
1) Checks before starting (ask the customer 3) Download cable (799-608-3220)
also to carry out this inspection) • For details of the setup method, see the instruc-
i) Check that the sensors are installed tion manual for the technical analysis tool box
properly. (for service).
(Check that there are no loose, dam- • The setup operation is carried out by trained per-
aged, or dirty mounts) sonnel under the guidance of the person respon-
• Blow-by sensor sible at your company. Or contact Komatsu.
• Engine oil temperature sensor
• Exhaust temperature sensor When replacing communications controller
• Ambient temperature sensor • In the following cases, there are important proce-
• Communications antenna dures to be carried out, such as opening and
ii) Check that there are no disconnected or closing of the communications controller, so fol-
damaged wiring harnesses, cables, or low the instruction of the person in charge at
connectors. your company. Or contact Komatsu.
iii) Check that there is no leakage of oil or 1) When replacing the controller installed on the
gas from the sensor mounts. machine with another controller.
2) Every 1000 hours service 2) When removing the controller installed on
i) Communications antenna one machine and installing it on another
• Check that there is no looseness at machine.
the antenna mount. 3) When disposing of the controller.
• Check that there is no damage or 4) When giving away or selling the machine
looseness of the antenna itself. with the controller installed.
• If there is any abnormality, replace 5) When disposing of a machine with a control-
the antenna. ler installed.
3) When required
i) If there is any abnormality in the down-
loaded values, check all sensors.
3. Remedy
If there is any abnormality, repair, replace, or
reinstall (tighten).
HD465-7, HD605-7 20-203-16

➁
TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS
Timing Operation step Operation step
-3 Setting up payload meter Click the PLT tag to

(Machine with PLM II or 1) Setting start time and interval (days) for
VHMS with PLM function) data collection
• In the example on the right, the start time
(For details of setting up PLM, see is set at 11 PM and the interval at 2 days.
the separate PLM instruction manual)
Click Apply to register the setting
Starting switch OFF Check the 7-segment display in the VHMS controller inspection window.
Saving of contents of setting • The display continues for several seconds after the starting switch is turned OFF. Check that
Turn the starting switch OFF to save the the saving-to-memory display goes out completely.
data in the VHMS controller.
Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller.
Starting switch ON * The normal operation of the LED means that the 7 segments flash in the rotation state after the
Check of normal operation of VHMS starting switch is turned to the ON position and then they count up in hexadecimal notation.
controller For details, see the Shop Manual.
Start engine [Outline of procedure]

Execution of quick Pm clinic 1) Execute the quick PM while the engine is warm.
Execute the quick Pm clinic according to 2) Select the service mode with the monitor panel, change the function, display "SNAPSHOT", and
the procedure shown in the Shop Manual. press the < > switch. Then, run the engine at Lo/Hi idle Be extremely careful about safety
and stall the torque converter in 7 minutes 30 seconds. when carrying out the torque
converter stall.
Starting switch OFF
Saving in VHMS Check lighting of the 7 segments in the inspection window of the VHMS controller.
Turn the starting switch OFF to save the • The segments keep lighting for several seconds after the starting switch is turned off. (Saving operation)
data in the VHMS controller. Check that the segments go off perfectly.
Starting switch ON Check that the VHMS controller is connected to the portable personal computer by the cable.
Download Start the "VHMS analysis tool" (VHMS technical analysis tool box) on the personal computer display.
Download all files.
For details, see the instruction manual for the
technical analysis tool box.
After downloading is finished, check the VHMS data with the
Check of downloaded data "VIEW" function.
• Check that the set contents are displayed correctly.
(Date, time, service meter, machine serial No., etc.)
• Check that the data of the quick Pm executed
in are saved in "Snap Shot".
Saving in VHMS
Turn the starting switch OFF to save the
data in the VHMS controller. 1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
power for the VHMS is turned OFF), if the all system is normal.
Starting switch OFF 2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
After returning to office This completes the initial setup of the VHMS.
Finish setting of the VHMS and The setup of the database (Web server) is carried out by Komatsu, so after you have
notify to KOMATSU completed the operation, inform Komatsu as follows.
Send the check sheet by fax.
Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS, WebCARE Support Center

(Service Business Development Group Customer Support Division Komatsu Head Office)
Welcome to WebCARE Tel: 03-5561-2765
Use WebCARE to check the data Fax: 03-5561-4766
https://wcare.komatsu.co.jp E-mail: webcare@komatsu.co.jp
Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM
controller
Setting with VHMS initial setting manual (tool)
PLM Set position of ( 1)
Card-type rotary switch 2
VHMS function in payload meter Payload meter Date
(SW2) of Set
controller VHMS (PLM) function Time
controller (PLM- ) transmission Model Type variation Time difference
controller code (GMT)
Summer time
Not installed — Not installed Not installed F — — — —
Not installed — Installed Installed F — — — —
Installed Not installed Not installed Not installed B ST
HD465 Set
Installed Not installed Installed Installed F or –7 P2
HD605 properly
Installed Installed Installed Installed 9 PV
" A variation code is an item among the model, date, etc. that are set with the personal computer software when the
VHMS is set initially. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV), whether PLM
is connected (Code: P2), and whether the machine has the payload meter (PLM) function (Code: ST)".
" Since A and B of the short connector to be connected to connector No. HM-50 are not used, connect them normally.
( 1) The transmission controller switch (SW2) is used to notify the monitor panel "whether the VHMS is installed",
"whether the PLM function in the VHMS is turned on", and "whether PLM- is installed". (See the section of
adjustment of the transmission controller.)
HD465-7, HD605-7 20-203-18

!
TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS INITIAL SET-UP CHECK SHEET sheet
(For HD465/605-7 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, hexadecimal count-up display)
Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up" ?
Initial setup of VHMS controller Is model name same as name of machine? yes no
–1 Set machine data Has machine serial No. been input correctly? yes no
Was selection of variation code set correctly? yes no
This sets the basic data for the machine Has engine serial No. been input correctly? yes no
in the VHMS controller. Has date been set to today's date? yes no
Has time been set to correct time? yes no
Save settings After saving operation, did LED (7 segments) go off? yes no
Setting of payload meter

–1 Check of functions of VHMS Did LED operate normally? yes no
–2 Starting of VHMS initial setting tool Is selection of mode of setting tool

yes no
"Set up"?
–3 Setting of payload meter Enter set value of PLM collection

(When PLM II or PLM function is installed) Time to start collection
Collection interval (day) day
Check VHMS functions Did LED operate normally? yes no
Perform quick PM clinic Were service mode and "SNAPSHOT" selected and
yes no
was switch pressed?
Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
Download Did LED operate normally? yes no
Check downloaded data Have all files been downloaded? yes no

Time of download (use wrist watch)
[Check data]
Is there any MFAO error in Fault History? yes no
In Fault History, do set values for SMR and
yes no
time match?
Are there any data missing in Snapshot? yes no
Are there any data in Transmission Shift Change Map? yes no
Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
Point of Contact VHMS, WebCARE Support Center

Tel: 03-5561-2765
Fax: 03-5561-4766
E-mail: webcare@komatsu.co.jp
20-203-19 HD465-7, HD605-7

(7)
TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE
Timing Operation step Operation step
Starting switch OFF Save to VHMS memory Check the 7-segment display in the VHMS controller inspection window.
Turn the starting switch OFF to save the • The display continues for several seconds after the starting switch is turned OFF.
data in the VHMS controller. Check that the saving-to-memory display goes out completely.
1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
power for the VHMS is turned OFF), if the all system is normal.
2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
After returning to office
Completing operation to set up VHMS This completes the setup for Orbcomm.
and contacting Komatsu The setup of the reception inside of the satellite communications is carried out by Komatsu,
　 so after you have completed the operation, inform Komatsu as follows.
Send the check sheet by fax.
Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS, WebCARE Support Center

Welcome to WebCARE Tel: 03-5561-2765
Use WebCARE to check the data Fax: 03-5561-4766
https://wcare.komatsu.co.jp E-mail: webcare@komatsu.co.jp
20-203-21 HD465-7, HD605-7

➄
TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS INITIAL SET-UP CHECK SHEET sheet
(For HD465/605-7 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Orbcomm controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, count-up display)
(Check operation of Orbcomm) Does VHMS monitor (7-segment) display decimal point?
yes no
(OFF, ON, Slow/Quick flash)
Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up"?
Initial setup of VHMS controller
–1 Set up communications Input set value of short Fault History

Condition of communications On Off
* (The setting of the machine data and PLM Number of items (default value: 8) items
is already completed) Input set value of short Trend Analysis
Interval (default value: 20 hrs) Hrs
Input set value of short Payload data
Time of start of data collection
Data collection interval (day) day
–2 Set start of communications Is GCC code set to 130 (if Japan) yes no
Point of Contact VHMS, WebCARE Support Center

Tel: 03-5561-2765
Fax: 03-5561-4766
E-mail: webcare@komatsu.co.jp
HD465-7, HD605-7 20-203-22

(7)
PERFORMING PM-CLINIC USING MANUAL
TESTING AND ADJUSTING SNAPSHOT (= QUICK PM)
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM)

What is quick Pm?
If a serious error occurs, the VHMS snapshot function saves all the data for a period of 5 minutes 30 seconds
before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds).
This snapshot function can be studied by pressing the manual switch. After the button is pressed, all data is
automatically saved for seven minutes 30 seconds. All data can be automatically collected in cases such as
torque converter stall, so it is possible to reduce the time taken for measurements in the Pm Clinic.
However, the data sampling interval is one time every 10 seconds for the first 5 minutes and one time every 1
second for the next 2 minutes 30 seconds. To raise the precision of the data, it is necessary to create the con-
ditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.
Necessary tools
• Personal computer
• VHMS technical analysis toolbox (software)
799-608-3211
• Download cable 799-608-3220
To ensure safety, stop the machine on flat

ground and put blocks under the tires to pre-
vent the machine from moving.
1. Start the engine.
2. Select SNAPSHOT with the monitor panel

(EMMS).
! For details of the method of selecting, see
Special functions of vehicle monitor (EMMS).
20-204 HD465-7, HD605-7

"
3. Press the [ ] button.

"READY" is displayed.
(Waiting status)
4. When the [ ] button is pressed, Snapshot is

started and the time advances.
(Running)
If you want to stop, press the [ ] button to return
to the Waiting status screen.
5. Run the engine at low idling and stabilize it for 2

minutes.
★ Check that the coolant temperature gauge
and torque converter oil temperature gauge
are in the white range.
6. After starting, operate the machine as shown in

Table 1.
Table 1
Measurement conditions
Start Finish Time Operation of machine Remarks
AISS switch Power mode Shift lever Parking Retarder Dump lever
setting brake
1 0 : 00 2 : 00 120 sec Low idling (Low) Auto Economy N ON ON Hold
2 2 : 00 3 : 00 60 sec Low idling (Hi) Auto Economy N OFF OFF Hold ( 1)
3 3 : 00 4 : 00 60 sec High idling (Stationary mode) Auto Economy N ON ON Float
4 4 : 00 5 : 00 60 sec Low idling (Hi) Auto Economy N ON ON Hold
5 5 : 00 5 : 30 30 sec High idling (Economy mode) Auto Economy N ON ON Hold
6 5 : 30 6 : 00 30 sec Torque converter stall (Economy mode) Auto Economy D OFF ON Hold ( 2, 3)
7 6 : 00 6 : 30 30 sec High idling (Power mode) Auto Power N ON ON Hold
8 6 : 30 7 : 00 30 sec Torque converter stall (Power mode) Auto Power D OFF ON Hold ( 2, 3)
High idling (Power mode)
9 7 : 00 7 : 30 30 sec + Auto Power N ON ON Hold
20 pumping operations of foot brake
( 1) Press the foot brake.

( 2) When stalling the torque converter [Portion marked with ( )], do not overheat it.
[Stall of torque converter for 30 seconds is only a reference. When the oil temperature gauge reaches the top of the
white range while the torque converter is stalled, return the transmission (gearshift) lever to the N position.]
( 3) When setting the gearshift lever in the D position, return the engine speed to low idling temporarily (to prevent the
machine from running out).
HD465-7, HD605-7 20-204-1

➄
7. After 7 minutes 30 seconds, the screen on the

right is displayed for 5 seconds, and then it
returns to the opening screen.
(Completion of Snapshot)
8. Download the snapshot data to the personal

computer. For details, see Procedure for down-
loading VHMS data to personal computer.
NOTICE
The quick PM data is only recorded once. If the
operation is carried out again, the data is over-
written, so after performing the quick PM, always
download the data to the personal computer.
9. Use the technical analysis tool box to read the

quick PM data.
★ For details of the method of using the techni-
cal analysis tool box, see the instruction
manual.
• Open the quick PM data and make a graph
• For the X-axis, select Time and for the Y-
axis, select
1) Engine Speed
2) Blowby Press
3) Exhaust Temp 1, 2 & 3
4) Exhaust Temp 4, 5 & 6
5) Engine Oil Press
and put a check mark against Graph value dis-
play at click position (marked by ).
20-204-2 HD465-7, HD605-7

➁
• If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph.
(Example of graph display)
• Enter these values on the Pm Clinic check sheet.

The relationship between the measurement conditions and the necessary data in the Pm Clinic is as
shown below.
Conditions Measurement items
Brake oil
Engine speed Mode Engine Blow-By Lublicating oil Exhaust pressure
speed pressure pressure temperature
( 1)
1 Low idle Low
2 Low idle High
3 High idle Stationary mode
4 Low idle Economy mode
5 High idle Economy mode
6 Torque converter Economy mode
stall
7 High idle Power mode
8 Torque converter Power mode
stall
High idle
9 + Power mode
20 pumping opera-
tions of foot brake
( 1) Cut OUT oil pressure and brake cut IN.
HD465-7, HD605-7 20-204-3

(9)
TESTING AND ADJUSTING PM-CLINIC SERVICE
HD465-7, HD605-7 20-205

(9)
20-206 HD465-7, HD605-7

(9)
HD465-7, HD605-7 20-207

(8)
TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................... 20- 302

Sequence of events in troubleshooting ..................................................................................................... 20- 303
Points to remember when carrying out maintenance................................................................................ 20- 304
Checks before troubleshooting ................................................................................................................. 20- 312
Categories, procedure, and method of using troubleshooting charts........................................................ 20- 313
Connection table for connector pin numbers ............................................................................................ 20- 318
T-adapter table .......................................................................................................................................... 20- 341
Types and locations of connectors ........................................................................................................... 20- 344
Connector arrangement location............................................................................................................... 20- 356
Troubleshooting of engine controller system (ENG mode) ....................................................................... 20- 401

Troubleshooting for transmission controller system (TM mode) ............................................................... 20- 501
Troubleshooting for retarder controller system (BK mode) ....................................................................... 20- 701
Troubleshooting for payload meter system (card type) (LC mode) ........................................................... 20- 801
Troubleshooting for monitor system (MON mode) .................................................................................... 20- 901
Troubleshooting of VHMS controller system (VHMS mode) ..................................................................... 20-1001
Troubleshooting of hydraulic and mechanical systems (H mode) .............................................................20-1101
Troubleshooting of engine system (S mode) ............................................................................................20-1151
HD465-7, HD605-7 20-301

(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. ﬂ When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from ﬂ The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 HD465-7, HD605-7

!
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
HD465-7, HD605-7 20-303

➁
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric equip-

ment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one
component to another component, connectors used
for connecting and disconnecting one wire from
another wire, and protectors or tubes used for protect-
ing the wiring.
Compared with other electrical components fitted in
boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection and repair
operations, they are frequently removed and installed
again, so they are likely to suffer deformation or dam-
age. For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact
between male and female)
Problems with defective contact are likely to occur
because the male connector is not properly inserted
into the female connector, or because one or both of
the connectors is deformed or the position is not cor-
rectly aligned, or because there is corrosion or oxi-
dization of the contact surfaces.
2) Defective crimping or soldering of connectors

The pins of the male and female connectors are in
contact at the crimped terminal or soldered portion,
but if there is excessive force brought to bear on the
wiring, the plating at the joint will peel and cause
improper connection or breakage.
20-304 HD465-7, HD605-7

➀
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
soldering may be damaged, or the wiring may be bro-
ken.
4) High-pressure water entering connector

The connector is designed to make it difficult for water
to enter (drip-proof structure), but if high-pressure
water is sprayed directly on the connector, water may
enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed to prevent
water from entering, but at the same time, if water
does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropri-
ate action before passing electricity through it.
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 surface between the male
and female pins, the oil will not let the electricity pass,
so there will be defective contact.
If there is oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air
and spray it with a contact restorer.
★ When wiping the mating portion of the connector,
be careful not to use excessive force or deform
the pins.
★ If there is oil or water in the compressed air, the
contacts will become even dirtier, so remove the
oil and water from the compressed air completely
before cleaning with compressed air.
HD465-7, HD605-7 20-305

➀
2) Removing, installing, and drying connectors and

wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the con-
nectors and not the wires. For connectors held by
a screw, loosen the screw fully, then hold the male
and female connectors in each hand and pull
apart. For connectors which have a lock stopper,
press down the stopper with your thumb and pull
the connectors apart.
★ Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted up and down or to
the left or right, the housing may break.
3) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from get-
ting in the connector portion.
★ If the machine is left disassembled for a long
time, it is particularly easy for improper con-
tact to occur, so always cover the connector.
20-306 HD465-7, HD605-7

➀
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
2) Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
3) Check that there is no damage or breakage to
the outside of the connector.
★ 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.
★ If there is any damage or breakage, replace
the connector.
2) Fix the connector securely.

Align the position of the connector correctly, then
insert it securely.
For connectors with lock stopper, push in the con-
nector until the stopper clicks into position.
3) Correct any protrusion of the boot and any mis-

alignment of the wiring harness
For connectors fitted with boots, correct any pro-
trusion of the boot. In addition, if the wiring har-
ness is misaligned, or the clamp is out of position,
adjust it to its correct position.
★ If the connector cannot be corrected easily,
remove the clamp and adjust the position.
4) If the connector clamp has been removed, be sure

to return it to its original position. Check also that
there are no loose clamps.
HD465-7, HD605-7 20-307

➀
• Since the DT 8-pole and 12-pole heavy duty wire con-

nectors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female conector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c
• Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it
off with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do
not use high-pressure water or steam directly on the
wiring harness.
If water gets directly on the connector, do as follows.

1) Disconnect the connector and wipe off the water
with a dry cloth.
★ If the connector is blown dry with compressed
air, there is the risk that oil in the air may
cause defective contact, so remove all oil and
water from the compressed air before blowing
with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
★ Hot air from the dryer can be used, but regu-
late the time that the hot air is used in order
not to make the connector or related parts too
hot, as this will cause deformation or damage
to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to check for
any short circuits between pins caused by water.
★ After completely drying the connector, blow it
with contact restorer and reassemble.
20-308 HD465-7, HD605-7

(6)
3) Handling control box

1) The control box contains a microcomputer and
electronic control circuits. These control all of the
electronic circuits on the machine, so be
extremely careful when handling the control box.
2) Do not open the cover of the control box unless
necessary.
3) Do not place objects on top of the control box.

4) Cover the control connectors with tape or a vinyl
bag.
Never touch the connector contacts with your
hand.
5) During rainy weather, do not leave the control box
in a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil,

or in any hot place, even for a short time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body, dis-
connect all wiring harness connectors connected
to the control box. Fit an arc welding ground close
to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
HD465-7, HD605-7 20-309

➀
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic

equipment, the most common cause of failure is dirt (for-
eign material) in the hydraulic circuit. When adding
hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly
careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repair-
ing the machine in rain or high winds, or places where
there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of
dust entering the equipment. It is also difficult to con-
firm the performance after repairs, so it is desirable to
use unit exchange. Disassembly and main-tenance of
hydraulic equipment should be carried out in a specially
prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the open-
ings should be sealed with caps, tapes, or vinyl bags
to prevent any dirt or dust from entering. If the open-
ing is left open or is blocked with a rag, there is dan-
ger of dirt entering or of the surrounding area being
made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground, collect it
and ask the customer to dispose of it, or take it back
with you for disposal.
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when refill-
ing with hydraulic oil. Always keep the oil filler and the
area around it clean, and also use clean pumps and
oil containers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collected during
storage, so this is an even more effective method.
20-310 HD465-7, HD605-7

➀
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows easily.
In addition, the sludge can also be drained out easily
from the circuit together with the oil, so it is best to
change the oil when it is still warm. When changing
the oil, as much as possible of the old hydraulic oil
must be drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from the
drain plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equipment,
or changing the oil, use flushing oil to remove the con-
taminants, sludge, and old oil from the hydraulic cir-
cuit.
Normally, flushing is carried out twice: primary flush-
ing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry out oil
cleaning to remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built into the
hydraulic equipment cannot remove, so it is an
extremely effective device.
HD465-7, HD605-7 20-311

➀
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

(1. Check before starting and 2. Other check items)
Item Judgement value Action
1. Check fuel level Fuel level Add fuel
2. Water, sediment in fuel tank Drain

lubricating oil,coolant
Hydraulic oil,
3. Check oil level in transmission case Sight gauge Drain
4. Check oil level in hydraulic tank Sight gauge Drain
5. Check oil level in engine oil pan Oil level gauge Add oil
6. Check coolant level — Add water
7. Check dust indicator Dust indicator Clean, replace
8. Check that steering wheel play is correct Max. 135 mm Adjust
9. Check emergency steering Actuation 20 sec Repair
10. Check length of suspension cylinder Label Repair

Air, hydraulic, mechanical components
11. Check tire inflation pressure, check for damage — Inflate or replace
Torque (see DISASSEM- Tighten
12. Check hub nuts
Check before starting items
BLY AND ASSEMBLY)
13. Check foot brake effect — Adjust
14. Check parking brake effect — Adjust or repair

1 15. Check that emergency brake works properly — Adjust or repair
16. Check that there is no abnormality in operation of steering — Adjust or repair
17. Check that direction of rear view mirror and under mirror is correct — Adjust
18. Check that there is no abnormality in exhaust color or sound — Adjust or repair
19. Check that retarder brake works properly — Adjust or repair
20. Check that body mount rubber is normal — Replace
21. Check that horn sounds — Repair
22. Check that lamps flash properly — Repair or replace

Electrical components
23. Check that gauges work properly during operation — Adjust or repair
24. Check monitor panel — Adjust or repair
25. Check mechanical monitor system — Repair or replace
26. Check central warning lamp — Adjust or repair
27. Check for looseness, corrosion of battery terminal wiring — Retighten or clean
28. Check for looseness, corrosion of alternator terminal wiring — Retighten or clean
29. Check for looseness, corrosion of starting motor terminal wiring — Retighten or clean
20-312 HD465-7, HD605-7

➁
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
Item Judgement value Action
30. Check for abnormal noise or smell — Repair

mechanical
equipment
Hydraulic,
31. Check for oil leakage — Repair
32. Air bleed operation — Bleed air
33. Check battery voltage (engine stopped) 24V Charge or replace

Other check items
Electrics, electrical components
34. Check battery electrolyte level — Add distilled water

35. Check wiring for discoloration, burn marks, peeling of — Replace
2 cover
36. Check for loose wiring clamps, hanging wiring — Repair
37. Check for wet wiring (be particularly careful to check connec- — Dry
tors and terminals)
38. Check for blown fuses, defective contact — Replace

39. Check alternator voltage after several minutes of running After operating for
Replace
(engine at 1/2 throttle or above) several minutes
40. Check for actuation sound from battery relay (when starting — Replace
switch is turned ON-OFF)
HD465-7, HD605-7 20-312-1

➁
CATEGORIES, PROCEDURE, AND METHOD OF
TROUBLESHOOTING USING TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING TROU-

BLESHOOTING CHARTS
1. Category of troubleshooting code
a If the machine monitor displays a failure code, it also displays the controller name at the same time, so
the troubleshooting codes are categorized to match each controuller name. (This may also include the
electrical system, where some failure codes are not displayed).
a The hydraulic and mechanical system, for which the machine monitor cannot display a failure code, is
categorized as H Mode.
Troubleshooting Code Troubleshooting System
ENG Troubleshooting of engine controller system
TM Troubleshooting for transmission controller system
BK Troubleshooting for retarder controller system
LC Troubleshooting for payload meter system (card type)
MON Troubleshooting for monitor system
HM Troubleshooting VHMS controller system
H Troubleshooting of hydraulic and mechanical systems
S Troubleshooting of engine body
2. Troubleshooting procedure
a If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as fol-
lows.
1) When machine monitor displays failure code
If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2) When machine monitor does not display failure code, but trouble data is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the
trouble data display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3) When machine monitor does not display failure code and trouble data is also not recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, and the
problem is also not recorded by the trouble data display function in the machine monitor service mode,
there is a probability that is a problem in the electrical system that cannot be detected by a controller or
that a problem has occurred in the hydraulic and mechanical system.
In this case, check the nature of the problem and go to the applicable troubleshooting chart.
HD465-7, HD605-7 20-313

(9)
Phenomena considered to be failures and troubleshooting No.

a With mark q go to troubleshooting No. on failure code display
Troubleshooting
No. Phenomena considered to be failures
Error ENG TM BK LC MON VHMS H S
code mode mode mode mode mode mode mode mode
Error code related
1 Error code is displayed in error code display mode q

Engine related
2 Starting performance is poor (starting always takes time) ENG-1 S-1
3 Engine does not turn S-2 a)

Engine does not Engine turns but no exhaust
4 start S-2 b)
smoke comes out
5 Exhaust smoke comes out but S-2 c)
engine does not start
6 Engine does not pick up smoothly (follow-up is poor) S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly (hunting) S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive S-8

(or exhaust smoke is blue)
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil is in cooling water, or water spurts back, or water S-11

level goes down
15 Oil pressure caution lamp lights up S-12
(drop in oil pressure)
16 Oil level rises S-13
17 Water temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
Engine is not preheated ENG-2a)

20 Failure in pre-
heating Engine is still preheated after pre- ENG-2b)
heating time
When AISS switch is set in AUTO, ENG-3a)
AISS function LOW SPEED control is selected
21 does not work
normally When AISS switch is set in LOW ENG-3b)
SPEED, AUTO control is selected
22 Not error code is displayed in error code display mode TM-
1 – 27
Transmission controller related
23 Fuel level gauge does not operate normally TM-1

(It always indicates "FULL")
When the shift lever is set in the
24 "R" position, the backup lamp and TM-2a)
backup buzzer are not turned ON
Abnormality in Backup lamp is not turned ON
25 backup lamp TM-2b)
(Backup buzzer is normal)
and backup
26 buzzer Backup buzzer is not turned ON TM-2c)
(Backup lamp is normal)
27 While shift lever is not operated, TM-2d)
backup lamp and backup buzzer
20-314 HD465-7, HD605-7

(9)
Troubleshooting
Retarder controller related
When the parking brake switch is
set in the OFF position, the park- BK-1a)
Parking brake ing brake s not released
28 does not oper-
ate normally When the parking brake switch is
set in the PARK position, the park- BK-1b)
ing brake does not work
29 Retarder brake oil temperature gauge does not oper- BK-2
ate normally
30 Inclination alarm is turned ON when dump body is BK-3
raised
31 Touch up/down and cancellation cannot be performed BK-4
Payload meter related
32 When starting switch is turned ON, any item is not dis- LC-1
played
33 After starting switch is turned ON, all external pilot LC-2
lamps do not light up
34 External lamps light up while condition for lighting is LC-3
not set
35 Lighting level of external pilot lamps is abnormal LC-4
36 Cycle data and engine ON/OFF data not recorded LC-5

(charge level signal system: judges that engine is
Calibration cannot be performed and displayed clock
37 does not conform to condition LC-6
(shift lever "N" position signal system)
38 When loaded dump truck starts LC-7a)
traveling, "0" is kept displayed
After loaded dump truck start trav-
39 eling, display of odometer does LC-7b)
not increase
Displayed logic
40 is abnormal When travel speed exceeds limit LC-7c)
speed, "SP:SP" does not go off
41 Integrated pay load is not dis- LC-7d)
played
42 Displayed and saved pay load is LC-7e)
not correct
Payload meter keeps displaying "b:FL"
43 (body "FLOAT" signal system: dump lever is not in LC-8
"FLOAT" position while truck is not dumping)
44 Payload meter displays "F:09" LC-9
(lowering of internal backup battery voltage)
45 Payload meter displays " :FULL" (data saving mem- LC-10
ory is full)
46 Payload meter displays "F-20" :failure in power source LC-11
of suspension pressure sensor and clinometer system
47 Payload meter displays "F-21" – "F-24" : disconnection LC-12
or grounding fault in suspension sensor signal system
48 Payload meter displays "F-25" – "F-28" : short circuit LC-13
with power source in suspension sensor signal system
49 Payload meter displays "F-CAL" LC-14
(negligence of calibration or internal damage of pay-
50 Payload meter displays "F:43" – "F:45" LC-15
(short circuit with power source in external pilot lamp relay
51 Payload meter displays "L-bad" LC-16
(cycle data were saved while truck body was pitching)
External pilot lamp indicates forecast while truck is not
52 being loaded or clock is displayed while truck travels LC-17
for 160 m after it is loaded
53 Payload meter displays "F-31" : grounding fault or dis- LC-18
connection in clinometer sensor signal system
54 Payload meter displays "F-32" : short circuit with LC-19
power source in clinometer sensor signal system
55 Payload meter displays "F:18" LC-20
(disconnection in charge level signal system)
HD465-7, HD605-7 20-315

(9)
Troubleshooting
Monitor related
56 When starting switch is turned ON, machine monitor MON-1

does not display any item
57 When starting switch is turned OFF and machine mon- MON-2
itor does not operate normally
Alarm buzzer does not sound MON-3a)
58 Alarm buzzer
defective Alarm buzzer does not stop sound- MON-3b)
ing
Items displayed Items displayed by gauges are dif- MON-4
by gauges, cau- ferent from machine condition
tion lamps, and Items displayed by caution lamps
59 character dis- MON-4
are different from machine condi-
play of machine
monitor are Character display does not display MON-4
abnormal any item or it displays abnormally
60 Operation of machine monitor cannot be checked nor- MON-5
mally
Display of char- Machine monitor mode select MON-6
acter display switch 1 system is abnormal
61 cannot be Machine monitor mode select MON-6
selected nor- switch 2 system is abnormal
62 Power mode select function does not work normally MON-7
Lamp lights up while seat belt is MON-8a)
Seat belt caution fastened
63 lamp does not
operate normally Lamp does not light up while seat MON-8b)
belt is unfastened
When turn signal lever and hazard
lamp switch are operated, any turn MON-9a)
signal lamp does not flash
When turn signal lever and hazard
lamp switch are operated, the turn MON-9b)
signal lamps do not flash but light
up
When turn signal lever is oper-
ated, turn signal lamps on either or
both sides do not flash (When MON-9c)
hazard lamp switch is operated,
Turn signals and however, turn signal lamps flash
hazard lamp do normally)
64 not operate nor- W h e n h a z a r d l a m p s w it c h i s
mally turned ON, any turn signal lamp
does not flash (When turn signal MON-9d)
lever is operated, however, turn
signal lamps flash normally)
W h e n h a z a r d l a m p s w it c h i s
turned OFF, turn signal lamps con-
tinue flashing (When turn signal MON-9e)
lever is operated, however, turn
signal lamps flash normally)
Turn signal pilot lamps do not flash
normally (Turn signal lamps flash MON-9f)
normally, however)
When lamp switch is set in 1st or
2nd position, any of small lamp, MON-10a)
night lamp, and head lamp does
not light up
When lamp switch is set in 1st
position, small lamp and night MON-10b)
Night lighting is lamp do not light up
65 abnormal When lamp switch is OFF, small MON-10c)
lamp and night lamp light up
When dimmer switch is operated,
brightness of night lighting does MON-10d)
not change
Head lamp "Hi" beam does not MON-10e)
light up
20-316 HD465-7, HD605-7

(9)
Troubleshooting
Head lamp "Lo" beam does not MON-10f)
light up
Abnormal in Head lamp cannot be set to "Hi" or
backup lamp MON-10g)
65 and bukup "Lo"
buzzer When head lamp is set to "Hi"
beam, pilot lamp of machine moni- MON-10h)
tor does not light up
Left window does not work MON-
Power window 11a)
66 does not oper-
ate normally Right window does not work MON-
11b)
Air conditioner does not operate MON-
12a)
Air is not blown out or airflow can- MON-
not be adjusted 12b)
Air is not cooled or temperature MON-
cannot be adjusted (Electric sys-
tem) 12c)
Inside air and fresh air cannot be MON-
selected 12d)
Defective air
67 MON-
conditioner Air outlet cannot be selected
12e)
Cooling capacity is low (Mechani- MON-
cal system) 12f)
Heating capacity is low MON-
(Defective hot water circuit) 12g)
Abnormal noise comes out MON-
12h)
Water leaks MON-
12i)
VHMS
Satellite communication data are
Abnormality in not transmitted
68 satellite data VHMS-1
communication Downloading into PC
69 Abnormality in saving in VHMS controller VHMS-2

(Data are not saved)
Engine blow-by pressure of monitoring display is low
70 (when measurement equipment shows blow-by pres- VHMS-3
sure is normal)
Hydraulic and mechanical related
71 Machine does not start H-1
72 Machine does not travel smoothly (machine jerks) H-2
73 Lock-up clutch cannot be disengaged (engine stalls) H-3
74 Excessive shock when starting or shifting H-4
75 Transmission does not shift up H-5
Abnormality at all speed ranges H-6a)

Machine lacks
76 power or speed Torque converter lock-up does not H-6b)
when traveling engage
Abnormality at specific speed H-6c)
ranges
77 Time lag is excessive when starting or shifting gear H-7
78 Torque converter oil temperature is high H-8
79 Torque converter oil pressure is low H-9
80 Front brake is ineffective, or effective only on one side H-10
81 Rear brake is ineffective, or effective only on one side H-11
HD465-7, HD605-7 20-317

(9)
Troubleshooting
82 Steering wheel is heavy H-12
83 Steering wheel does not work H-13
84 Steering wheel vibrates H-14
85 Hoist cylinder lacks lifting force (lifting speed) H-15
86 Hoist cylinder does not work H-16
87 Excessive hydraulic drift of dump body H-17
20-317-1 HD465-7, HD605-7

(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
No. X-type connector

of T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part no.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

• Terminal part no.: 79A-222-3370 • Terminal part no.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: black • Grommet: black
• Quantity: 20 • Quantity: 20
• Terminal part no.: 79A-222-3380 • Terminal part no.: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-318 HD465-7, HD605-7

➀
No. SWP-type connector

of T-adapter
Part No.
6 799-601-7050
Part No.: 08055- 10681 Part No.: Part No.: 08055- 10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055- 10891
12 799-601-7310
Part No.: 08055- 11281 Part No.: 08055- 11291
14 799-601-7070
Part No.: 08055- 11481 Part No.: 08055-11491
HD465-7, HD605-7 20-319

➀
No. SWP-type connector

of T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

• Terminal part no.: • Terminal part no.:
— —
• Grommet: black • Grommet: black
• Terminal part no.: • Terminal part no.:
— —
• Grommet: red • Grommet: red
20-320 HD465-7, HD605-7

➀
No. M-type connector

of T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
HD465-7, HD605-7 20-321

(7)
S-type connector
No.
of pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(white)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(white)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(white)
Part No.: 08056-11671 Part No.: 08056-11681
20-322 HD465-7, HD605-7

!
S-type connector
No.
of pins T-adapter
Part No.
10
—
(blue)
— —
12
799-601-7160
(blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(blue)
Part No.: 08056-11672 Part No.: 08056-11682
HD465-7, HD605-7 20-323

!
MIC type connector

No.
of pins T-adapter
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7 —
Qty.: 5 Qty.: 5
1 —
Qty.: 5 Qty.: 5
5 799-601-2710

Qty.: 5 Qty.: 5
9 799-601-2950

Qty.: 5 Qty.: 5
13 799-601-2720

Qty.: 2 Qty.: 2
20-324 HD465-7, HD605-7

(7)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730

Qty.: 2 Qty.: 2
21 799-601-2740

Qty.: 2 Qty.: 2
—
Qty.: 50 Qty.: 50
HD465-7, HD605-7 20-325

➀
AMP040-type connector
No. of
pins T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

—
Qty.: 5
12 799-601-7190

—
Qty.: 5
16 799-601-7210

—
Qty.: 5
20 799-601-7220

—
Qty.: 5
★ Terminal part No.: 79A-222-3470 (no relation with number of pins)
20-326 HD465-7, HD605-7

➀
AMP070-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7360
20 799-601-7550
— Part No.: 7821-92-7370
HD465-7, HD605-7 20-327

(9)
L type connector
No. of
pins T-adapter
Part No.
—
2
— — —
PA type connector
No. of
pins T-adapter
Part No.
— —
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
— —
20-328 HD465-7, HD605-7

➀
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
2 —
Part No.: 08027-10210 (natural color) Part No.: 08027-10260 (natural color)
08027-10220 (black) 08027-10270 (black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (black) 08027-10470 (black)
6 —
08027-10620 (black) 08027-10670 (black)
HD465-7, HD605-7 20-329

➀
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
8 —
08027-10820 (black) 08027-10870 (black)
20-330 HD465-7, HD605-7

➀
Connector for relay (socket type)

No. of
pins T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
HD465-7, HD605-7 20-331

➀
F-type connector
No. of
pins T-adapter
Part No.
4 —
— —
20-332 HD465-7, HD605-7

➀
Type HD30 series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
799-601-9210
(1) Pin (female terminal) Pin (male terminal)
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
HD465-7, HD605-7 20-333

➀

Part No.
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-334 HD465-7, HD605-7

➀

Part No.
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

Part No.: 08191-61201, 08191-62202 Part No.: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
HD465-7, HD605-7 20-335

➀

Part No.
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Part No.: 08191-81201, 08191-81202, 08191- Part No.: 08191-84101, 08191-84102, 08191-
81203, 08191-81204, 08191-81205, 08191- 84103, 08191-84104, 08191-84105, 08191-
24-22 81206 84106
799-601-9280
Part No.: 08191-82201, 08191-82202, 08191- Part No.: 08191-83101, 08191-83102, 08191-
82203, 08191-82204, 08191-82205, 08191- 83103, 08191-83104, 08191-83105, 08191-
82206 83106
20-336 HD465-7, HD605-7

➀

Part No.
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
HD465-7, HD605-7 20-337

➀
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-338 HD465-7, HD605-7

➀
DT series connector
No. of
pins T-adapter
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9090
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
HD465-7, HD605-7 20-339

(7)
DTM series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD series connector

No. of
pins T-adapter
Part No.
Part No.: 08192 - 31200 (contact size #12) Part No.: 08192 - 31100 (contact size #12)
08192 - 41200 (contact size #8) 08192 - 41100 (contact size #8)
08192 - 51200 (contact size #4) 08192 - 51100 (contact size #4)
20-340 HD465-7, HD605-7

$
[The pin No. is also marked on the connector (electric wire insertion end)]
DRC26 Series connector

No.of
pins T-adapter Part
No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
HD465-7, HD605-7 20-340-1

(9)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P ! ! ! ! ! !

799-601-3100 For measuring box MS-37P !
799-601-3200 For measuring box MS-37P !
799-601-3300 For measuring box Econo-24P !
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P ! !
799-601-3420 BENDIX(MS) 24P ! !
799-601-3430 BENDIX(MS) 17P ! !
799-601-3440 BENDIX(MS) 17P ! !
799-601-3450 BENDIX(MS) 5P ! !
799-601-3460 BENDIX(MS) 10P ! !
799-601-3510 BENDIX(MS) 5P ! !
799-601-3520 BENDIX(MS) 14P ! !
799-601-3530 BENDIX(MS) 19P ! !
799-601-2910 BENDIX(MS) 14P ! !
799-601-3470 CASE !
799-601-2710 MIC 5P ! ! ! !
799-601-2720 MIC 13P ! ! ! !
799-601-2730 MIC 17P ! ! ! ! ! ! !
799-601-2740 MIC 21P ! ! ! ! ! ! !
799-601-2950 MIC 9P ! ! ! !
799-601-2750 ECONO 2P ! !
799-601-2760 ECONO 3P ! !
799-601-2770 ECONO 4P ! !
799-601-2780 ECONO 8P ! !
799-601-2790 ECONO 12P ! !
799-601-2810 DLI 8P ! !
799-601-2820 DLI 12P ! !
799-601-2830 DLI 16P ! !
799-601-2840 Extension cable ! ! !
799-601-2850 CASE !
799-601-7010 X 1P ! !
799-601-7020 X 2P ! ! ! !
799-601-7030 X 3P ! ! ! !
799-601-7040 X 4P ! ! ! !
799-601-7050 SWP 6P ! ! !
799-601-7060 SWP 8P ! ! !
799-601-7310 SWP 12P !
799-601-7070 SWP 14P ! !
HD465-7, HD605-7 20-341

➀
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7320 SWP 16P !

799-601-7080 M 1P ! !
799-601-7090 M 2P ! ! ! !
799-601-7110 M 3P ! ! ! !
799-601-7120 M 4P ! ! ! !
799-601-7130 M 6P ! ! ! !
799-601-7340 M 8P !
799-601-7140 S 8P ! ! ! !
799-601-7150 S 10P-White ! ! ! !
799-601-7160 S 12P-Blue ! ! !
799-601-7170 S 16P-Blue ! ! ! !
799-601-7330 S 16P-White !
799-601-7350 S 12P-White !
799-601-7180 AMP040 8P !
799-601-7190 AMP040 12P ! !
799-601-7210 AMP040 16P ! ! ! !
799-601-7220 AMP040 20P ! ! ! !
799-601-7230 Short connector X-2 ! ! ! !
799-601-7240 Case ! !
799-601-7270 Case !
799-601-7510 070 10P !
799-601-7520 070 12P !
799-601-7530 070 14P !
799-601-7540 070 18P !
799-601-7550 070 20P !
799-601-7360 Relay connector 5p !
799-601-7370 Relay connector 6p !
799-601-7380 JFC connector 2P !
799-601-9010 DTM 2P ! !
799-601-9020 DT 2P ! !
799-601-9030 DT 3P ! !
799-601-9040 DT 4P ! !
799-601-9050 DT 6P ! !
799-601-9060 DT 8P-Gray ! !
799-601-9070 DT 8P-Black ! !
799-601-9080 DT 8P-Green ! !
799-601-9090 DT 8P-Blown ! !
799-601-9110 DT 12P-Gray ! !
799-601-9120 DT 12P-Black ! !
799-601-9130 DT 12P-Green ! !
799-601-9140 DT 12P-Blown ! !
799-601-9210 HD30 18-8 ! !
799-601-9220 HD30 18-14 ! !
20-342 HD465-7, HD605-7

➀
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 Q Q

799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For boost pressure,
799-601-9420
fuel
3P Q
799-601-9430 PVC socket 2P Q
HD465-7, HD605-7 20-343

(9)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

Address
Con- Type Num- 3-dimen-
nector of ber Location sional System diagram
No. connector of pin wiring
diagram ENG TM BK PLM MON VHMS ASR
01 Terminal 1 Battery relay (B) B9 J-1 K-8 H-9 K-9 N-9
02 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
03 Terminal 1 Battery relay (B) B9 J-1 K-8 H-8 K-8 N-8
04 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
05 Terminal 1 Emergency steering relay (B) A8 K-9
06 Terminal 1 Emergency steering relay (M) A8 K-9
07 Terminal 1 Emergency steering relay (B) A8 J-1 K-8 H-9 K-9
08 Terminal 1 Emergency steering relay (M) A9 J-1 K-8 H-8 K-8
11 Terminal 1 Battery relay (E) B-8 J-1 J-1 K-8
12 Terminal 1 Battery relay (BR) B-8 J-1 J-1 K-8 H-8 K-8
12 KES0 2 Washer tank motor — J-1 H-8 K-8
13 Terminal 1 Battery relay (E) C-8 J-1 K-8 H-8 K-8 N-8
14 Terminal 1 Battery relay (BR) C-8 H-8 K-8 N-8
15 Terminal 1 Emergency steering relay (E) A-8 K-9
16 Terminal 1 Emergency steering relay (BR) A-7 K-9
17 Terminal 1 Emergency steering relay (E) B-7 K-9
18 Terminal 1 Emergency steering relay (BR) B-7 K-8
20 — 1 Circuit breaker A-9 L-8 N-8
21 — 1 Circuit breaker A-9 L-8 N-7
22 — 1 Circuit breaker A9 J-2 K-8 I-8 L-8 N-8
23 — 1 Circuit breaker B9 I-2 K-8 I-8 L-8 N-7
1939 HD30 9 Connector for connecting J1939 device — G-9 A-3
A One-pin 1 Lamp (Optional for payload meter) — J-9

connector
A One-pin 1 Lamp (Optional for payload meter) — H-1
connector
A1 M 1 Emergency reset connector X6 B-7
A2 M 1 Emergency reset connector V8 B-7
AAPR PACKARD 3 Air pressure sensor AH5 B-1
ABS M 6 ABS system switch O2 E-9
AC1 One-pin
connector 1 Air conditioner wiring harness M3 C-7
ACBM YAZAKI 2 Air conditioner blower motor T2 A-9
ACCF DT-T 3 ACC oil pressure sensor (Front) L4 L-2 K-4
ACCR DT-T 3 ACC oil pressure sensor (Rear) K3 L-2 K-4
ACM1 AMP 5 Temperature regulation servomotor V3 A-8
ACM2 AMP 5 Air outlet mode selection servomotor M6 B-9
20-344 HD465-7, HD605-7

!
Address
Con- Type Num-
3-dimen-
Recirculated/Fresh air selection
ACM3 AMP 5 servomotor W3 A-7
ACP1 AMP 16 Air conditioner control panel O7 B-9
ACP2 AMP 12 Air conditioner control panel O7 B-9
ACPS SUMITOMO 2 Air conditioner pressure switch U2 A-8
ACR1 Relay 4 Blower main relay W3 A-8
ACR2 Relay 4 Blower Hi relay W4 A-8
ACR3 Relay 4 Blower M2 relay W4 A-7
ACR4 Relay 4 Blower M1 relay W4 A-7
ACR5 Relay 4 Compressor clutch relay W4 A-7
ACRE AMP 4 Air conditioner blower resistor U2 A-8
ACTH YAZAKI 2 Thermistor U3 A-8
AISS M 6 AISS switch M3 L-5
ARC M 3 ARSC set switch P8 F-9
ARSC M 6 ARSC system switch N3 C-1 F-9
AS1 SWP 6 Acceleration sensor N2 L-2
AS2 X 3 Acceleration sensor O2 C-8
ASR M 6 ASR system switch O2 F-9 F-5
ASR1 DT-T-T 2 Steering angle sensor C2 C-9
ASR2 DT-T-T 2 Shut off valve L2 D-9
ASR3 DT-T-T 2 ASR valve (R) K3 D-9
ASR4 DT-T-T 2 ASR valve (L) L3 E-9
ASR5 DT-T 2 ASR oil pressure switch (R) K3 E-9
ASR6 DT-T 2 ASR oil pressure switch (L) L2 F-9
ASR7 DT-T 2 ASR oil ptessure switch (Main) K1 F-9
ASS DT-T 2 Air suspension seat T2
ATC1 MIC 17 Transmission controller Z1 L-8 A-7 E-1 E-1 H-1
ATC2 MIC 21 Transmission controller Z1 A-7
ATC3A AMP040 20 Transmission controller Z4 L-8 A-6 E-1 E-1
ATC3B AMP040 16 Transmission controller Z4 A-6 E-1
ATC4 AMP040 12 Transmission controller AA4 L-7 A-5 E-1 F-1 I-1
ATC5A AMP040 20 Transmission controller AA1 L-7 A-5
ATC5B AMP040 16 Transmission controller AA4 A-4
ATC6 X 4 Software rewriting connector

(Transmission controller) W4 A-3
B01 DT-T 6 Intermediate connector K9 M-5
B02 DT-T 6 Intermediate connector K8 M-5
HD465-7, HD605-7 20-345

➄
Address
B03 DT-T 6 Winker lamp, stop lamp, tail lamp J9 M-6
B04 Terminal 1 Backup lamp J9 F-9 M-6
B05 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B06 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B07 DT-T 3 Body position sensor K9 K-5
B1 One-pin
connector 1 Lamp (Optional for payload meter) — I-9
B1 One-pin 1 Lamp (Optional for payload meter) — H-1

connector
B10 Terminal 1 Grounding K8 G-9 M-4
B11 Terminal 1 Grounding L8 M-5
B2 One-pin 1 Lamp (Optional for payload meter) — J-9

connector
B2 One-pin
connector 1 Lamp (Optional for payload meter) — H-1
B3 One-pin 1 Lamp (Optional for payload — J-9

connector meter)
B3 One-pin 1 Lamp (Optional for payload — H-1
connector meter)
BCOM One-pin 1 Beacon lamp T9 A-2
connector
BK DT-T
(Gray) 8 Intermediate connector F9 H-2 M-2
BL One-pin 1 Intermediate connector C7 I-8

connector
BLS M 6 Rotary lamp switch (Optional) N1 C-9
BR One-pin 1 Air conditioner wiring harness M4 C-7

connector
BRC1 MIC 17 Retarder controller Y2 J-9 C-1 A-8 D-1 H-1
BRC2 MIC 21 Retarder controller Y2 A-7 A-1
BRC3A AMP040 20 Retarder controller Y4 C-1 A-6 D-1 B-1
BRC3B AMP040 16 Retarder controller Y4 A-5
BRC4 AMP040 12 Retarder controller Z4 J-9 C-1 A-5 D-1 H-1
BRC5A AMP040 20 Retarder controller Y1 A-4
BRC5B AMP040 16 Retarder controller Y2 C-1 A-3 D-1
BRC6 X 4 Software rewriting connector

(Retarder controller) S9 A-2
BT DT 6 Intermediate connector C9 I-2 H-6 G-8 J-6 M-9
BT1 — — Fuse box X5 E-3 E-7 K-3
BT2 — — Fuse box X7 L-4 E-2 F-3 E-7 I-3 F-4
BT3 — — Fuse box X6 L-4 E-2 F-3 E-6 K-3
BT4 — — Fuse box X6 L-3 E-2 E-6 I-3
BZ2 M 2 Buzzer R1 D-9
CAB1 DT-T 8 Intermediate connector Q9 F-1

(Gray)
CAB2 DT-T 8 Intermediate connector Q9 B-9
(Black)
CAN DT 3 CAN connector AJ6 H-9 L-6 M-3 A-2
20-346 HD465-7, HD605-7

➄
Address
CAN1 DT-T 3 VHMS CAN connector T9 C-9
CAN2 DT-T 3 Resistor Q1 F-9 D-9
CG1 One-pin 1 Cigarette lighter M5

connector
CG2 — 1 Cigarette lighter M5
CH1 S 8 Machine monitor mode selector switch 1 M1 E-9
CH2 S 8 Machine monitor mode selector switch 2 M1 E-9
CJA DT-T 6 Joint connector D8 L-9
CJB DT-T 8 Joint connector B7 I-1 M-9

(Black)
CJB DT-T 6 Joint connector E8 L-9
CJC DT-T 6 Joint connector D8 G-8 H-9
CJD DT 6 Joint connector D8 H-9 H-9 M-9
CJE2 DT-T 6 Joint connector AI9 G-1 M-1
CJE3 DT-T 8 Joint connector A12 G-1 M-1 L-3 K-1 N-7
(Black)
DT-T
CJH1 (Black) 8 Joint connector — I-9 J-1 M-1
CJH2 DT-T 6 Joint connector — J-1 J-1
CJK DT 6 Joint connector B8 I-1 J-9 H-9 J-9 M-9
CJL DT-T 6 Joint connector L7 I-1 M-1
CJN DT (Black) 8 Joint connector J3 I-1
CJP DT-T 6 Joint connector I9 I-1 J-1
CJP1 DT-T 6 Joint connector H9 I-1
CJP2 DT-T 6 Joint connector I9 H-1
CJPR DT-T 6 Joint connector C8 I-9
CJS DT-T 6 Joint connector L7 N-5
CJSL DT-T 6 Joint connector I9 I-1
CJT DT 8 Joint connector L8 G-9 N-5

(Black)
CJT1 DT-T 8 Joint connector L7 G-1
(Black)
CJT2 DT-T 6 Joint connector H9 G-1
CJW DT-T 6 Joint connector F-7
CK1 YAZAKI 6 Bulb breakage check switch M2 F-9
CLTP PACKARD 2 Cooling water temperature sen- AE8 A-1

sor
CM DT-T 8 Lighting switch, passing switch, turn Q8 B-2
(Green) switch
CN3 DT-T 2 Input shaft speed sensor AC9 M-8
CN4 DT-T 2 Intermediate shaft speed sensor AC9 M-8
CN5 DT-T 2 Output shaft speed sensor AD7 M-8 G-2 K-4
CN6 DT-T 2 Solenoid for transmission 1st clutch AB9 M-6
HD465-7, HD605-7 20-347

➄
Address
CN7 DT-T 2 Fill switch for transmission 1st clutch AB9 N-6
CN8 DT-T 2 Solenoid for transmission 2nd clutch AB9 M-6
CN9 DT-T 2 Fill switch for transmission 2nd clutch AA9 N-6
CN10 DT-T 2 Solenoid for transmission R clutch AA9 M-6
CN11 DT-T 2 Fill switch for transmission R clutch AA9 N-6
CN12 DT-T 2 Solenoid for transmission 3rd clutch AA9 M-6
CN13 DT-T 2 Fill switch for transmission 3rd clutch AA9 N-6
CN14 DT-T 2 Solenoid for transmission 4th clutch AA9 M-5
CN15 DT-T 2 Fill switch for transmission 4th clutch Z9 N-5
CN16 DT-T 2 Solenoid for transmission L clutch Z8 M-7
CN17 DT-T 2 Fill switch for transmission L clutch Z8 N-6
CN18 DT-T 2 Solenoid for transmission H clutch Y8 M-7
CN19 DT-T 2 Fill switch for transmission H clutch Y7 N-7
CN20 DT-T 2 Solenoid for torque converter lockup Z8 M-7

clutch
CN21 DT-T 2 Fill switch for torque converter lockup
clutch Z8 N-7
CN22 DT-T 3 Torque converter intermediate pres- Z5 M-8

sure sensor
CN23 DT-T 2 Torque converter oil temperature AA5 M-7
sensor
CN24 DT-T 2 Transmission valve oil temperature AC5 M-7
sensor
CNS1 DT-T 12 Intermediate connector H-8
(Brown)
CNS2 DT-T 12 Intermediate connector B-9 B-2 H-8
(Green)
CNS3 DT-T 12 Intermediate connector A-9 E-7
(Black)
COM One-pin
connector 1 Air conditioner wiring harness M3 C-7
D01 DT-T 2 Diode V8 L-5 C-9 F-8 F-8 I-9
D02 DT-T 2 Diode W8 A-1 F-1
D03 DT-T 2 Diode W8 F-1
D04 DT-T 2 Diode M6 A-8
D05 DT-T 2 Diode W8 A-1 E-1
D07 DT-T 2 Diode P2 I-9
D08 DT-T 2 Diode W8 K-5 C-9 F-8 F-8 I-9
DL DT-T 12 Intermediate connector X6

(Black)
DPC1 AMP070 20 Machine monitor P8 I-9 E-9 C-1 A-7
DPC2A AMP070 18 Machine monitor P1 A-6
DPC2B AMP070 12 Machine monitor P1 C-1 A-6 F-1
DPC3A AMP070 18 Machine monitor P8 A-5
DPC4 AMP070 12 Machine monitor Q1 I-9 E-9 D-9 A-5
20-348 HD465-7, HD605-7

➄
Address
DPC6 AMP040 8 Machine monitor O7
DPC7 X 4 Software rewriting connector N3

(Machine monitor)
DSL — 1 Door switch (Left) F1
DSR — 1 Door switch (Right) T2
DT7 DT-T 12 Intermediate connector T2 D-2 F-1
DT8 DT-T 4 Intermediate connector J2
E Terminal 1 Emergency steering motor L-9
E01 Terminal 1 Alternator AE7 H-1 N-3 L-4 K-3 N-7
E02A DT-T 2 Starting motor AH1 H-2 M-3
E02B DT-T 2 Starting motor AH1 G-2 M-2
E03 DT-T 2 Engine speed sensor AF1 N-3
E04 DT-T 2 Oil level switch (Optional) AH5 M-3
E05 Terminal 1 Oil filter switch C2 H-9
E06 Terminal 1 Alternator AE6, H-1 N-4

AF1
E07 DT-T 2 Compressor AF8 N-7
E08 DT-T 2 Diode AG9
E09 Terminal 1 Alternator AE6 H-1 N-3
E10 Terminal 1 Grounding AG9
E11A Terminal 1 Heater relay AJ9 F-3 N-5
E11B Terminal 1 Ribbon heater AH9 F-2 N-4
E12A Terminal 1 Heater relay AJ9 F-3 N-4
E12B Terminal 1 Ribbon heater AG9 F-1 N-4
E13A DTHD 1 Intermediate connector AG1 I-2 K-5

(#4)
E13B DTHD 1 Intermediate connector AG1 H-2 K-5
(#4)
E15 Terminal 1 Grounding AI2 G-1 M-3
E16A Terminal 1 Grounding AI9 F-3 N-5
E16B Terminal 1 Grounding AH9 F-2 N-4
E17A DT-T 2 Diode AJ8 F-3 N-5
E17B DT-T 2 Diode AJ8 F-2 N-4
E2B DT 2 Diode AE5 A-3
ECM A DRC26 40 Engine controller AG5 A-8 L-1 K-8 M-4
ECM B DRC26 40 Engine controller AG9 C-8 L-1 K-8 M-4 B-3
EG4 DT-T 12 Intermediate connector V9

(Brown)
ENG DT-T 8 Intermediate connector AJ7 H-2 H-3 J-7 J-3 M-7
(Gray)
ER Terminal 1 Grounding C9, C8, I-1 J-8 H-8 J-7 M-8
E9, G9
HD465-7, HD605-7 20-349

➄
Address
ER1 Terminal 1 Grounding P1 D-8 F-7
ER2 Terminal 1 Grounding X7 H-6 A-8 C-1 B-7 F-1
ER3 Terminal 1 Grounding O2
FBC M 6 Front brake cutting switch N3 G-9
FL01 DT-T 2 Radiator water level sensor B3 H-9
FL04 YAZAKI 2 Washer motor B3 M-1
FL05 DT-T 2 Air conditioner dual switch B2 L-1
FLB — 1 Flasher R1 A-4
FLL — 1 Flasher R1 A-4
FLTP PACKARD 2 Fuel temperature sensor AF9 A-1
FOG M 6 Fog lamp switch (Optional) N1 C-9
FR01 DT-T 2 Air cleaner clogging sensor B7 G-9
FS2 One-pin 2 Spare terminal X6

connector
connector
FS4 One-pin
connector 2 Spare terminal X7

connector
FS8 One-pin 2 Spare terminal X6 J-4
connector
FSO– Terminal 1 Fuel shut-off valve – AE7 E-1
FSO+ Terminal 1 Fuel shut-off valve + AE7 E-1
FUA Terminal — Fuse box (30 A) C9 K-2 L-9 I-9 L-9 N-8
FUB Terminal — Fuse box (120 A x 2) C9 K-1 L-9
G One-pin 1 Lamp (Optional for payload meter) — I-9

connector
G One-pin 1 Lamp (Optional for payload meter) — H-1
connector
G21 Terminal 1 Grounding S1 B-7
GND Terminal 1 Engine block GND AF8 E-2 K-1 L-8 M-4
H01 DT-T 2 Steering flow switch K3
H10 One-pin 1 Heater unit M4

connector
H20 One-pin 1 Heater unit M4
connector
HAZ M 6 Hazard switch O7 G-9
HEAT DT 2 Heater control AJ7 F-6 J-2
HEPC DT-T 2 Hoist EPC valve L5 L-2
HES Terminal 1 Grounding —
HN One-pin 1 Horn switch Q8 D-9

connector
HN1A — 1 Horn valve A4 L-9
HN1B — 1 Horn valve A4 L-9
20-350 HD465-7, HD605-7

➄
Address
HN2A — 1 Horn valve A4
HN2B — 1 Horn valve A3
HSL DT-T 4 Intermediate connector V3 D-1
HSL DT-T 4 Hoist lever potentiometer V3 D-1
HSOL DT-T 3 Hoist selector valve L5 L-2
HTA DT-T
(Gray) 8 Intermediate connector L6 I-8 J-3
HTB DT-T 8 Intermediate connector L6 I-8 K-3 J-4 M-2

(Black)
IMPR PACKARD 3 Intake air pressure sensor AF8 B-1
IMTP PACKARD 2 Intake air temperature sensor AF8 B-1
J01 HD30 9 Intermediate connector I2 G-4 F-6 H-7 G-7 I-6
J02 HD30 31 Intermediate connector I2 G-3 F-6 H-7 G-6 I-6 C-7
J03 HD30 31 Intermediate connector I2 F-6 H-6 G-5 I-5 C-7
J04 HD30 31 Intermediate connector H1, H-5 G-4 I-5 C-6

AN6
J05 HD30 31 Intermediate connector H1, F-5 H-4 G-4
AN6
J07 HD30 14 Intermediate connector H1 F-5 H-3 G-4 C-5
J08 HD30 31 Intermediate connector G1 F-5 C-4
J09 HD30 31 Intermediate connector G1 G-6 F-4 H-4 I-5 C-4
J10 HD30 31 Intermediate connector G1 G-4 F-4 H-3 G-3 I-5 C-3
JC01 DT 6 Joint connector AI6 A-4
JC02 DT (Black) 8 Joint connector AI5 A-5
JC03 DT (Black) 8 Joint connector AH5 A-5
JC04 DT (Black) 8 Joint connector AG5 A-6 K-1 L-7 M-4
JC11 DT 6 Joint connector AG5 E-9 K-1
JC12 DT 6 Joint connector AH5 E-9
JC13 DT (Black) 8 Joint connector AI5 F-9 K-1 L-7
JC14 DT (Black) 8 Joint connector AI6 G-9 K-1 L-7 M-3 A-2
JC15 DT 6 Joint connector AI6 H-9 L-1 L-6 M-3
JCA DT-T 8 Joint connector X5 E-1

(Black)
JCB DT-T 8 Joint connector X5 K-6 C-1 A-1 C-1 G-1
(Black)
JCC DT-T 8 Joint connector X5 K-6 B-1 A-2 C-1 G-1
(Black)
JCD DT-T
(Black) 8 Joint connector X4 K-6 B-1 A-1 C-1 G-1
DT-T
JCE (Black) 8 Joint connector X4 K-7 B-1 A-2 C-1 G-1
JCF DT-T
(Black) 8 Joint connector S9 J-8 D-1 A-3 E-1 H-1
JCG DT-T 8 Joint connector V3 K-8 A-3 F-1 F-1 I-1

(Black)
JT1 DT-T 6 Joint connector AD7 J-1
HD465-7, HD605-7 20-351

➄
Address
JT2 DT-T 6 Joint connector AD7 J-1
LINK DT 6 Data link crossover AJ6 F-7 J-3 K-7
LKO DT-T 2 Intermediate connector U3 D-1
LKO DT-T 2 Lever kick-out solenoid V3 D-1
LP DT (Gray) 12 Intermediate connector I2 H-8 K-2
LS M 3 Rheostat M1 D-9
M Terminal 1 Emergency steering motor K-9
MON1 One-pin
connector 1 Rear view monitor (Optional) N7 I-9
MON2 One-pin 1 Rear view monitor (Optional) N7 I-9

connector
MON3 One-pin 1 Rear view monitor (Optional) O7 I-9
connector
MS11 M 1 Model selection connector U9 A-4
(Transmission controller)
MS32 M 1 Model selection connector V3 A-4
OLPR PACKARD 3 Engine oil pressure sensor AE5 B-1
OP1 M 1 Machine monitor setting connector M8, A-5

N9
N9
O9
M8,
OP4 M 1 Machine monitor setting connector O9 A-5
OP5 M 1 M8,
Machine monitor setting connector O9 A-5
OP6 M 1 Machine monitor setting connector N8, A-5

O8
OP7 M 1 Machine monitor setting connector N8, A-4
O8
OPS DT-T 2 Seat heater T2
PL01 M 2 Left head lamp (LOW) D1 J-1
PL02 M 2 Left head lamp (HIGH) D2 J-1
PL03 One-pin 1 Clearance lamp E1 K-1

connector
PL04 One-pin 1 Clearance lamp E1 K-1
connector
PL05 One-pin 1 Turn signal E1 K-1
connector
PL06 One-pin 1 Fog lamp (Optional) D1 J-1
connector
PL07 Terminal 1 Grounding C2 K-1
PM1 MIC 21 VHMS wiring harness T9 D-8, F-7,

E-9 D-7 H-7
PM3 DT-T 3 Pitch angle sensor X7 A-4
PM4 S (Natural 16 VHMS wiring harnes T9 I-8 E-7 D-8 C-8 F-6,
color) H-6
20-352 HD465-7, HD605-7

➄
Address
PM5 MIC 13 Payload meter controller T9 E-9 A-9 G-8
PM6 AMP040 12 Payload meter controller U9 I-8 E-9 D-9 A-9 G-8
PM7 AMP 9 VHMS wiring harnes H-8
PM7 AMP 9 Payload meter controller N7
PM8 BENDIX 5 Connector N7 K-5
PM9 MIC 21 VHMS wiring harness T9 E-9 H-7
PM10 S (Natural 16 VHMS wiring harnes T9 E-9 H-6

color)
PM11 MIC 21 Intermediate connector V9
PMLA DT-T 12 Intermediate connector H9 I-3

(Gray)
PMPR PACKARD 3 Fuel pump pressure sensor AF5 C-1 I-7
PMRA DT-T 6 Intermediate connector D8
POW HD30 21 Intermediate connector AJ7 F-4 H-4 J-7
PR01 M 2 Right head lamp (LOW) A5 K-9
PR02 M 2 Right head lamp (HIGH) A4 J-9
PR03 One-pin 1 Clearance lamp A5 K-9

connector
PR04 One-pin 1 Clearance lamp A5 K-9
connector
PR05 One-pin 1 Turn signal A5 K-9
connector
PR06 One-pin 1 Fog lamp (Optional) A6 J-9
connector
PR07 Terminal 1 Grounding A4 K-8
PSOL DT-T 2 Parking brake solenoid L6 L-3
PSW DT-T 2 Parking brake switch K3 L-3
PUMP PACKARD 3 Fuel pump actuator AF5 D-1

One-pin
PWL connector 1 Power window motor (Left) I2 F-1
PWM M 6 Power mode switch M4 G-9
PWR One-pin 1 Power window motor (Right) C7 F-1

connector
R One-pin
connector 1 Lamp (Optional for payload meter) J-9
R One-pin 1 Lamp (Optional for payload meter) H-1

connector
R01 Relay 5 Engine starting relay AB4 G-7 B-2
R02 Relay 5 Transmission Neutral relay AB3 B-2 A-8
R03 Relay 5 Parking brake relay AB3 A-9
R04 Relay 5 Brake lamp relay (RL) AB3 D-1
R05 Relay 6 Backup lamp, buzzer relay AB2 B-1 D-1
R06 Relay 6 Fog lamp relay AC4 D-1
R07 Relay 5 AISS relay AB4 H-8
R08 Relay 5 Brake lamp relay (CTR) AB3 E-1
HD465-7, HD605-7 20-353

➄
Address
R09 Relay 5 Brake lamp timer relay AB2 A-9 E-1
R10 Relay 5 PLM GDL relay AC4 A-7
R11 Relay 5 Horn relay AC4 D-1
R14 Relay 5 Brake cutting relay AB4 A-8
R15 Relay 5 Transmission cutting relay A2 B-2
R16 Relay 6 Hazard relay 1 AB1 C-1
R17 Relay 5 Hazard relay 2 AC1 C-1
R19 Relay 5 Parking brake safety relay AC4 A-8
R21 Relay 6 Side lamp relay AC4 A-6
R22 Relay 5 Rotary lamp relay AD3 B-1
R25 YAZAKI 11 Power window relay AC1 B-1
R29 Relay 5 Head lamp Hi relay AD2 C-1
R30 Relay 5 Head lamp Lo relay AD1 B-1
R32 Relay 5 Dust indicator relay AC1 B-3
R33 Relay 6 Parking brake manual switch R9 E-8
R34 YAZAKI 7 Power window switch (Left) S1 H-9
R35 YAZAKI 7 Power window switch (Right) S9 H-9
R37 Relay 5 Auto preheater relay AD3 G-8 B-3
R40 Relay 6 Payload meter relay (Optional) AD2 A-6
R43 Relay 5 Green outside pilot lamp relay of AD2 A-5

payload meter
Yellow outside pilot lamp relay of
R44 Relay 5 payload meter AD2 A-5
R45 Relay 5 Red outside pilot lamp relay of

payload meter AD1 A-5
RAD YAZAKI 9 AM/FM radio O2
RAIL PACKARD 3 Fuel rail actuator AF5 D-1
RDC YAZAKI 9 Cassette stereo O2
RE1 YAZAKI 2 Resistor S9 C-9 A-8
RE2 YAZAKI 2 Resistor S9 A-7
RE3 YAZAKI 2 Resistor P8 F-9
RE4 YAZAKI 2 Resistor P8 F-9
RESW DT-T 2 Retarder switch L4 L-1 N-1
RETV DT-T 2 Retarder valve L4 L-1
RL YAZAKI 2 Room lamp E9
RL2 One-pin 1 Room lamp 2 G9

connector
RP DT-T 6 Intermediate connector A6 K-8
RPR PACKARD 3 Fuel rail pressure sensor AI6 C-1
20-354 HD465-7, HD605-7

➄
Address
Con- Type Num-
3-dimen-
RT2 Terminal 1 Emergency steering timer M4
RTL DT-T 6 Retarder potentiometer P8 C-9 C-8
S01 DT-T 2 Service brake switch B7 G-2 N-2
S02 DT-T 2 Secondary brake switch E9 G-2 N-2
S03 DT-T 2 Front brake cutting solenoid (Optional) E9 G-2
S04 DT-T 2 Auto suspension solenoid 1 (Optional) F9 H-2
S05 DT-T 2 Auto suspension solenoid 2 (Optional) F9 H-1
SBS DT-T 2 Seat belt switch U2 F-1
SDE M 6 Side lamp switch (Optional) N2 A-7
SF1 DT-T 12 Shift lever R9 B-9 B-2 H-9

(Green)
SF2 DT-T 2 Shift lever Q9
SIG HD30 31 Intermediate connector AJ7 F-6 H-4 J-7 J-5 B-3
SLG Terminal 1 Grounding C8 I-8
SLG Terminal 1 Grounding J2 I-2
SLL M 1 Side lamp (Optional) J2 G-2
SLR M 1 Side lamp (Optional) C7 J-9
S-NET MS3102A
14S 5 S-NET monitor T1 A-9
SP1 PACKARD 2 Engine speed sensor (Master) AJ8 A-1
SP2 PACKARD 2 Engine speed sensor (Backup) AJ8 A-1
SPA1 DT-T 4 Spare connector 1 C-6
SPA2 DT-T 12 Spare connector 2 C-5
SPA3 DT-T 6 Spare connector 3 F1
SPL YAZAKI 2 Speaker (Left) G9
SPR YAZAKI 2 Speaker (Right) F9
SR2 X 3 Steering speed sensor P1 F-9
SR3 X 2 Pitch angle sensor X7 B-1
SUFL DT-T 3 Suspension oil pressure sensor(FL) H1 H-1 K-5

(Optional)
SUFR DT-T 3 Suspension oil pressure sensor(FR) B7 G-9 K-6
(Optional)
SURL DT-T 3 Suspension oil pressure sensor(RL) L8 K-5 K-5
(Optional)
SURR DT-T 3 Suspension oil pressure sensor(RR) J9 K-5 K-5
(Optional)
T01 DT-T 2 Fuel level gauge sensor G9 I-9
T02 DT-T 6 Retarder oil temperature sensor H9 J-8
HD465-7, HD605-7 20-355

➄
Address
Con- Type Num-
3-dimen-
T05 Terminal 1 Grounding I9 K-1
T1 Terminal 1 Grounding AC9 I-3
TEST One-pin 1 TEST switch V8 F-5

connector
TG One-pin 1 Tachograph S9
connector
TG2 One-pin 1 Tachograph S9
connector
TIMG PACKARD 3 Timing rail actuator AG9 D-1
TM2 HD30 21 Intermediate connector AD8 H-5 J-4
TM3 HD30 31 Intermediate connector AD8 H-5
TMF DT-T 2 Transmission oil filter sensor J3 I-9
TPR PACKAR 3 Timing rail pressure sensor AI6 C-1

D
TR — 6 Brake lamp timer X7 E-1
VHM DT-T 8 Intermediate connector C2

(Black)
WFM M 6 Front wiper motor Q1 A-4
WFR Relay 6 Front wiper relay R1 A-3
WPS DT-T
(Black) 12 Wiper switch Q8 B-3
WSRL DT-T 2 Wheel speed sensor (RL) K1 B-9
WSRR DT-T 2 Wheel speed sensor (RR) K1 C-9
VHMS controller related
CAN1 DT-T 3 VHMS intermediate connector AU2 E-5
DLSW Terminal 1 Ground level download box A01 A-7
EG4 DT-T 12 VHMS intermediate connector AV3 E-6
GDL DT-T 12 Ground level download box inter- AP4 A-6

mediate connector
GR1 Terminal 1 Ground level download box AP2 A-7
GR2 Terminal 1 Ground level download box AP2 A-7
HM-12 DT-T 3 Blow-by sensor AM6 B-4
HM-21A DT 2 Exhaust temperature sensor AN8 B-2
HM-21B DT 2 Exhaust temperature sensor AN7 B-2
HM-22A DT 2 Exhaust temperature sensor - amp AR8 J-2

intermediate connector
HM-22B DT 2 Exhaust temperature sensor - amp AQ7 J-2
HM-23A DT-T 3 VHMS - exhaust temperature amp AR8 J-2
VHMS - exhaust temperature amp
HM-23B DT-T 3 intermediate connector AQ7 J-2
HM-31 DT 2 Engine oil temperature sensor AN1 B-4
HM-35 DT 2 Ambient temperature sensor AM1 B-8
HM50 DT-T 3 Short connector AU2 H-8
HM55 DT-T 3 Short connector AQ6 I-8
20-355-1 HD465-7, HD605-7

➄
Address
Con- Type Num-
3-dimen-
HM81 M 8 VHMS - Orbcomm controller inter- AT2 L-3
mediate connector
HM-2130 Yasaki 2 Resistor AQ2 H-8
HM-2140 Yasaki 2 Resistor AR2 H-8
HM-CN1 AMP070 20 VHMS controller AS8 I-8
HM-CN2A AMP070 18 VHMS controller AT7 J-8
HM-CN2B AMP070 12 VHMS controller AU7 J-8
HM-CN3A AMP070 18 VHMS controller AT8 J-8
HM-CN3B AMP070 12 VHMS controller AS8 K-8
HM-CN4A AMP070 14 VHMS controller AU7 K-8
HM-CN4B AMP070 10 VHMS controller AT8 L-8
LM1 Terminal 1 Ground level download box lamp

terminal AP3 B-7
LM2 Terminal 1 Ground level download box lamp AP3 B-7

terminal
ORB-A AMP070 14 Orbcomm controller AS2 K-2
ORB-B AMP070 10 Orbcomm controller AS2 L-2
PDL MS 5 Ground level download box PLM AP2 A-7

connector
PLM MS 5 PLM II download connector AQ6 K-4
PM1 MIC 21 PLM II intermediate connector AV3 F-7,

H-7
PM4 S 16 PLM II intermediate connector AU7 F-6,
H-6
PM11 MIC 21 VHMS intermediate connector AV6 E-5
Ambient temperature sensor
SPA1 DT-T 4 intermediate connector AO6 C-6
SPA2 DT-T 12 Ground level download box AO6 C5

VDL MS 5 Ground level download box VHMS AP3 A-7
connector
VHM DT-T 8 Blow-by, oil temperature sensor in- AM6 B-4
termediate connector
VHMS MS 5 VHMS download connector AT2 K-4
WAKE Terminal 1 Ground level download box AP2 A-7
HD465-7, HD605-7 20-355-2

➄
TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION
CONNECTOR ARRANGEMENT LOCATION
20-356 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-357

➄
20-358 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-359

➀
20-360 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-361

➀
VHMS control related

(1/2)
20-362 HD465-7, HD605-7

➁
(2/2)
HD465-7, HD605-7 20-363

➁
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(ENG MODE)
Electrical system diagram related engine control ...................................................................................... 20-404

Information in troubleshooting table ............................................................................................................ 20-406
[C111KT] Abnormality in engine controller memory ............................................................................ 20-408
[C112LK] Abnormality in timing rail actuator ....................................................................................... 20-408
[C113KZ] Abnormal current in timing rail actuator system .................................................................. 20-409
[C115KZ] Abnormality in engine speed sensor 2 systems .................................................................. 20-410
[C116KX] Abnormally high level in timing rail pressure sensor system ............................................... 20-412
[C117KX] Abnormally low level in timing rail pressure sensor system ................................................ 20-413
[C118KX] Abnormally high level in fuel pump pressure sensor system ............................................... 20-414
[C119KX] Abnormally low level in fuel pump pressure sensor system ................................................ 20-415
[C121LC] Abnormality in engine speed sensor 1 systems .................................................................. 20-415
[C122KX] Abnormally high level in boost pressure sensor system ...................................................... 20-416
[C123KX] Abnormally low level in boost pressure sensor system ....................................................... 20-417
[C131KX] Abnormally high level in throttle sensor system .................................................................. 20-418
[C132KX] Abnormally low level in throttle sensor system .................................................................... 20-420
[C135KX] Abnormally high level in engine oil pressure sensor system ............................................... 20-421
[C141KX] Abnormally low level in engine oil pressure sensor system ................................................ 20-422
[C143ZG] Lowering of engine oil pressure ........................................................................................... 20-422
[C144KX] Abnormally high level in engine coolant temperature sensor system .................................. 20-423
[C145KX] Abnormally low level in engine coolant temperature sensor system ................................... 20-424
[C148KX] Abnormality in FM throttle: Out of input signal range .......................................................... 20-425
[C151NS] Rise of engine coolant temperature ..................................................................................... 20-426
[C153KX] Abnormally high level in air intake temperature sensor system .......................................... 20-427
[C154KX] Abnormally low level in air intake temperature sensor system ............................................ 20-428
[C221KX] Abnormally high level in atmospheric pressure sensor system ........................................... 20-429
[C222KX] Abnormally low level in atmospheric pressure sensor system ............................................ 20-430
[C234NI] Over-speed .......................................................................................................................... 20-430
[C254KZ] Abnormal voltage of fuel shut-off valve ................................................................................ 20-431
[C259FS] Abnormality in fuel shut-off valve ......................................................................................... 20-432
[C261NS] Abnormal rise of fuel temperature ....................................................................................... 20-432
[C263KX] Abnormally high level in fuel temperature sensor system ................................................... 20-433
[C265KX] Abnormally low level in fuel temperature sensor system ..................................................... 20-434
[C316KZ] Abnormal current of fuel pump actuator .............................................................................. 20-435
[C318LK] Abnormality in fuel pump actuator ....................................................................................... 20-436
[C346KT] Abnormality in power-down unit of engine controller ........................................................... 20-437
[C423L6] Abnormality in in-range of timing rail pressure sensor system ............................................ 20-439
[C431L4] Abnormality in idling validation switch system: See separate list (L4)
(Both signal voltages of 2 systems are sensed) ................................................................. 20-441
[C432L5] Error in idling validation process ( See separate list (L5)) ................................................ 20-443
[C441KK] Abnormally low level in battery voltage system .................................................................. 20-445
[C442KG] Abnormally high level in battery voltage system .................................................................. 20-445
[C451KX] Abnormally high level in fuel rail pressure sensor system ................................................... 20-446
[C452KX] Abnormally low level in fuel rail pressure sensor system .................................................... 20-447
[C455KZ] Abnormal current of fuel rail actuator .................................................................................. 20-448
HD465-7, HD605-7 20-401

➁
[C467LK] Abnormality in timing rail actuator control ........................................................................... 20-449
[C468LK] Abnormality in fuel rail actuator control ................................................................................ 20-449
[C514LK] Abnormality in fuel rail actuator .......................................................................................... 20-450
[C551L4] Abnormality in idling validation switch system: See separate list (L4)
(Either signal voltage of 2 systems is not sensed) ............................................................... 20-451
[C554L6] Abnormality in in-range of fuel rail pressure sensor system ................................................ 20-453
ENG-1 Engine does not start............................................................................................................ 20-455
ENG-2 Failure in preheating ............................................................................................................. 20-459
a) Engine is not preheated................................................................................................... 20-459
b) Preheating is actuated even under non-actuation conditions for preheating................... 20-462
ENG-3 AISS function does not work normally .................................................................................. 20-464
a) When AISS switch is set in AUTO, LOW SPEED control is selected.............................. 20-464
b) When AISS switch is set in LOW SPEED, AUTO control is selected.............................. 20-465
20-402 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL

Engine serial No. : 310169 – 310414
20-404 HD465-7, HD605-7

(9)
HD465-7, HD605-7 20-405

➁
Engine serial No. : 310415 – 310798
20-405-1 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-2

(8)
Engine serial No. : 310799 and up
20-405-3 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-4

(8)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

★ The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Error code Controller code

Display on Display on Display on Trouble Trouble in machine
panel panel panel
Contents of trouble Contents of trouble detected by monitor panel or controller
Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble
Problem that
Problem that appears on machine as result of action taken by monitor panel or controller (shown above)
appears on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in harness>
• Disconnection
Connector is connected imperfectly or harness is broken.
• Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in con-
2 tact with chassis ground circuit.
• Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
• Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes Possible causes of trouble
and standard value (Given numbers are refer- <Precautions for troubleshooting>
3
in normal state ence numbers, which do not
Method of indicating connector No. and handling of T-adapter
indicate priority) Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
• If connector No. has no marks of "male" and "female", disconnect
connector and insert T-adapters in both male side and female
side.
4 • If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female side.
Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front
side.
5
• Connect negative (–) lead to pin No. or harness entered on rear
side.
20-406 HD465-7, HD605-7

➀
Related electrical circuit diagram
Part of electric circuit diagram related to trouble

• Connector No.: Indicates (Model – Number of pins) and (Color).
• Arrows (⇔): Indicate rough location of connector in machine.
TROUBLE CODE TABLE

★ Regarding trouble code provided with instruction "Refer to table", check it against table below.
Trouble code Contents of trouble Trouble code Contents of trouble
KA Disconnection in wiring L0 Fill signals at two or more channels which are not set as combi-
nation are turned ON at the same time.
KB Short circuit L1 Fill signal is ON when command current to ECMV is OFF.
KK Source voltage reduction/ L2 Fuel pressure is above maxim specified value.

input
KQ Type select signal incon- L3 Object part is uncontrollable.

sistency
KR Defective communication L4 ON and OFF signals at two systems are inconsistent.
Engine rotation signal, terminal C signal, oil pressure switch
KT Abnormality in controller L6 signal, water temperature sensor signal, etc. are inconsistent
with operation state or stop state.
KX Outside input signal range L8 Analog signals in two systems are inconsistent.
KZ Disconnection or short cir- LC rpm signals in two systems are inconsistent.

cuit
MA Malfunction LD Switch is pressed for usually unthinkable long time.
MB Performance reduction LH Fill signal is OFF when command current to ECMV is ON.
MW Sliding
NS Overheat
ZG Oil pressure reduction
ZK Coolant level reduction
HD465-7, HD605-7 20-407

➀
TROUBLESHOOTING [C111KT], [C112LK]
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY
Action code Error code Controller code Abnormality in engine controller memory
Trouble
E03 C111KT ENG (Engine controller system)
Contents of trouble • Memory in controller has trouble or processor in controller has communication trouble.
Action of controller • Flashes caution lamp and turns on caution buzzer.
Problem that
• Engine cannot be started.
appears on machine
Related information • Method of reproducing error code: Turn starting switch ON.

Reset according to following procedure. If service code E is displayed
Possible causes
at this time, engine controller is defective.
and standard value
in normal state 1 Defective engine controller 1) Keep starting switch at OFF position for 5 seconds.
2) Run engine at low idling.
3) Check error code.
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR
Action code Error code Controller code Abnormality in timing rail actuator
Trouble
E03 C112LK ENG (Engine controller system)
• Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble • Judgment value (for reference):
Error is above 400 mm3/st or below –750 mm3/st (When water temperature is below 0°C).
• Flashes caution lamp and turns on caution buzzer.
Action of controller
• Limits engine speed to 1,500 rpm.
Problem that
• Engine speed lowers.
appears on machine
Related information • Method of reproducing error code: Start engine.

Check displayed service codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
Possible causes leakage.
piping
and standard value
3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
in normal state
Clogging of timing rail actua-
4 Check timing rail actuator screen directly for clogging.
tor screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
20-408 HD465-7, HD605-7

➀
TROUBLESHOOTING [C113KZ]
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM
Action code Error code Controller code Abnormal current in timing rail actuator system
Trouble
E03 C113KZ ENG (Engine controller system)
• Current in timing rail actuator is out of normal range.
Contents of trouble
• Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Problem that • Engine output lowers.
appears on machine • Exhaust gas becomes white.
• Special cable (795-799-5470) is necessary for troubleshooting for timing rail actuator.
Related information
• Method of reproducing error code: Turn starting switch ON (or start engine).

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective timing rail actuator TIMG (male) Resistance
1
(Internal trouble)
Between – 7–9Ω
Between , – chassis ground Min. 100 kΩ
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between ECMA (female) –
2 (Disconnection in wiring or Resistance Max. 10 Ω
TIMG (female)
defective contact in connec-
tor) Wiring harness between ECMA (female) –
Resistance Max. 10 Ω
TIMG (female)
Possible causes
and standard value ★ Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON
Short circuit in wiring har- Short circuit of wiring harness between ECMA
ness (female) – TIMG (female) with wiring Resistance Min. 1 M Ω
3
(with another wiring har- harness around it
ness) Short circuit of wiring harness between ECMA
(female) – TIMG (female) with wiring Resistance Min. 1 M Ω
harness around it
ECMA (female) Resistance
Wiring harness between , –
Min. 1 M Ω
wiring harness around it
Circuit diagram related to timing rail actuator
HD465-7, HD605-7 20-409

➀
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS
Action code Error code Controller code Abnormality in engine speed sensor 2 systems
Trouble
Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems.
• Outputs speed signal of 0 rpm.
Problem that
• Engine stops.
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 01001, 01002: Engine speed)
Related information
• Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.
• Method of reproducing error code: Start engine.

aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON
SP1 (male), SP2 (male) Resistance
Defective engine speed sen-
1 sor Between (2) – (1) and (3) – (4) 1 – 2 kz
(Internal trouble) Between (2) – (3) Max. 10 z
Between (1) – (4) Max. 10 z
Between (2), (3) – chassis ground Min. 10 Mz
Damage of engine speed
2 Check engine speed sensor directly.
sensor
aPrepare with starting switch OFF, then carry out troubleshooting
Wiring harness between ECMA (female) (27) –
Disconnection in wiring har- Resistance Max. 10 z
SP1 (female) (2)
ness
3 (Disconnection in wiring or Resistance Max. 10 z
SP1 (female) (1)
tor) Wiring harness between ECMA (female) (37) –
Resistance Max. 10 z
SP2 (female) (3)
Possible causes Resistance Max. 10 z
SP2 (female) (4)
and standard value
in normal state aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit of wiring harness between ECMA
(female) (27) – SP1 (female) (2) with wiring Resistance Min. 1 Mz
harness around it
ness (female) (28) – SP1 (female) (1) with wiring Resistance Min. 1 Mz
4
harness around it
harness around it
aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective engine controller Between (27) – (28) 1 k – 2 kz
Between (37) – (38) 1 k – 2 kz
20-410 HD465-7, HD605-7

(8)
Circuit diagram related to engine speed sensor
HD465-7, HD605-7 20-411

(8)
TROUBLESHOOTING [C116KX]
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in timing rail pressure sensor system
Trouble
CALL C116KX ENG (Engine controller system)
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Action of controller • Opens and controls timing rail.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
• Special cable (795-799-5460) is necessary for troubleshooting for timing rail pressure sensor.
Related information

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective timing rail pres-
1 sure sensor TIMG Voltage
(Internal trouble) Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Disconnection in wiring har-
ness Resistance Max. 10 Ω
TPR (female)
2 (Disconnection in wiring or
defective contact in connec- Resistance Max. 10 Ω
TPR (female)
tor)
Possible causes TPR (female)
in normal state without turning starting switch ON.
Short circuit in wiring har- (female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
ness
3 Short circuit of wiring harness between ECMA
(with another wiring har-
ness) (female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
(female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
4 Defective engine controller ECMA Voltage
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to timing rail pressure
20-412 HD465-7, HD605-7

➀
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in timing rail pressure sensor system
Trouble
E03 C117KX ENG (Engine controller system)
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.30 V
Action of controller • Opens and controls timing rail.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard value
in normal state Carry out troubleshooting for error code [C116KX].
HD465-7, HD605-7 20-413

➀
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
• Opens and controls fuel pump.
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for fuel pump pressure sensor.
Related information

Defective fuel pump pres-
1 sure sensor PMPR (male) Voltage
Between – 0.42 – 0.58 V
PMPR (female)
tor) PMPR (female)
Possible causes PMPR (female)
Short circuit in wiring har- (female) – PMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
ness
ness) (female) – PMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
(female) – PMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
4 Defective engine controller ECMA (female) Resistance
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-414 HD465-7, HD605-7

➀
TROUBLESHOOTING [C119KX], [C121LC]
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
• Opens and controls fuel pump.
Problem that
appears on machine

and standard value
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS
Action code Error code Controller code Abnormality in engine speed sensor 1 systems
Trouble
E01 C121LC ENG (Engine controller system)
Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems.
Problem that
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related information (Code 01001: Engine speed)

and standard value
HD465-7, HD605-7 20-415

➀
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in boost pressure sensor system
Trouble
Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.72 V.
Action of controller •
Problem that • When machine is accelerated sharply, exhaust gas color is bad.
appears on machine • Engine output rises.
• Special cable (799-795-5480) is necessary for troubleshooting for boost pressure sensor.
Related information

Defective boost pressure
1 sensor IMPR (male) Voltage
Between – 0.42 – 0.58 V
IMPR (female)
tor) IMPR (female)
Possible causes IMPR (female)
Short circuit in wiring har- (female) – IMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
ness
ness) (female) – IMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
(female) – IMPR (female) with wiring Resistance Min. 1 MΩ
harness around it
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to boost pressure sensor
20-416 HD465-7, HD605-7

➀
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in boost pressure sensor system
Trouble
Contents of trouble • Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
• Engine output lowers.
appears on machine

and standard value
HD465-7, HD605-7 20-417

➀
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in throttle sensor system
Trouble
Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4.80 V.
• Keeps engine speed at constant level.
Problem that
• Engine output and speed rise suddenly.
appears on machine
• Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring
mode.
Related information
(Code 31701: throttle potentiometer voltage)
• Method of reproducing error code: Turn starting switch ON.

Defective throttle potentiom- AS1 (male) Resistance
1 eter
Between – 4.0 – 6.0 kΩ
(Internal trouble)
Between – 0.25 – 7.0 kΩ
Between – 0.25 – 7.0 kΩ
Wiring harness between ECMB (female) –
AS1 (female)
Wiring harness between ECMB (female) –
tor) AS1 (female)
Possible causes Wiring harness between ECMB (female) –
and standard value AS1 (female)
in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit of wiring harness between ECMB
Short circuit in wiring har- (female) – AS1 (female) with wiring har- Resistance Min. 1 MΩ
ness around it
ness
3 Short circuit of wiring harness between ECMB
ness) (female) – AS1 (female) with wiring har- Resistance Min. 1 MΩ
ness around it
(female) – AS1 (female) with wiring har- Resistance Min. 1 MΩ
ness around it
ECMB Voltage
Between – 0.30 – 4.80 V
20-418 HD465-7, HD605-7

➀
Circuit diagram related to deceleration potentiometer
HD465-7, HD605-7 20-419

➀
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in throttle sensor system
Trouble
Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.
• Keeps engine speed at constant level.
Problem that
• Engine speed and output lower suddenly.
appears on machine
• Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring
mode.
Related information
(Code 31701: throttle potentiometer voltage)

and standard value
in normal state Carry out troubleshooting for erroe code [C131KX].
20-420 HD465-7, HD605-7

➁
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information

Defective engine oil pres-
1 sure sensor OLPR Voltage
Between – 0.42 – 0.58 V
OLPR (female)
OLPR (female)
tor)
Possible causes OLPR (female)
Short circuit in wiring har- (female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
ness
ness) (female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
(female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to engine oil pressure sensor
HD465-7, HD605-7 20-421

➁
TROUBLESHOOTING [C141KX], [C143ZG]
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in engine oil pressure sensor system
Trouble
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
Problem that
appears on machine

and standard value
[C143ZG] LOWERING OF ENGINE OIL PRESSURE
Action code Error code Controller code Lowering of engine oil pressure
Trouble
E03 C143ZG ENG (Engine controller system)
• Engine oil pressure sensor detected pressure lower than pressure set in controller.
• Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

Check displayed error codes. If code related to engine controller is dis-
Possible causes 1 Defective related systems
played, carry out troubleshooting for it first.
and standard value
in normal state Defective engine oil pres-
2 Carry out troubleshooting for error codes [C135KX] and [C141KX].
sure sensor system
3 Defective engine See Shop Manual for engine (170-3 Series).
20-422 HD465-7, HD605-7

➀
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE

SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor.
Related information

Defective engine coolant without turning starting switch ON.
1 temperature sensor
CLTP Resistance
(Internal trouble)
Between – 600 – 36 kΩ
ness
2 (Disconnection in wiring or Wiring harness between ECMA (female) –
CLTP (female)
Possible causes Resistance Max. 10 Ω
CLTP (female)
and standard value
in normal state
ness (female) – CLTP (female) with wiring Resistance Min. 1 MΩ
3
(female) – CLTP (female) with wiring Resistance Min. 1 MΩ
harness around it
Circuit diagram related to engine coolant temperature sensor
HD465-7, HD605-7 20-423

➀
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR

SYSTEM
Action code Error code Controller code Abnormally low level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-424 HD465-7, HD605-7

➀
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE

Trouble Abnormality in FM throttle: Out of input signal range
E03 C148KX ENG
Contents of trouble • The frequency of the FM throttle is below 150 Hz or above 400 Hz.
• The controller turns the alarm lamp and alarm buzzer on.
• The throttle sensor signal is conformed to the idling validation switch (In idling: 0%, Off idling: 35%).
Problem that
• The engine speed is kept at low idling or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

1) Turn the starting switch OFF.
Disconnection in wiring har- 2) Disconnect connector ECM.
ness 3) Connect T-adapter.
1
(Disconnection or defective
Wiring harness between ECMB (female)
contact) Resistance Max. 10 Ω
and ATC3A (female)
2) Disconnect connectors ECMB and ATC3A.
3) Connect T-adapter.
Grounding fault in wiring
2 Resistance value between
harness Wiring harness between
ECMB (female) , ATC3A
Possible causes ECMB (female) and Min. 1 MΩ
(female) and chassis
and standard value ATC3A (female)
ground
in normal state
2) Disconnect connector ATC3A.
3) Insert T-adapter.
Transmission controller de- 4) Connect the connector.
3
fective 5) Turn the starting switch ON.
Between ATC3A (male) and chassis
Frequency 170 – 380Hz
ground
1) Connect all the connectors.
2) Turn the starting switch ON.
4 Engine controller defective
• Check that the error code disappears.
★ If the error code does not disappear, replace the engine controller.
Circuit diagram related to engine abnormality in FM throttle
HD465-7, HD605-7 20-425

➁
TROUBLESHOOTING [C151NS]
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE
Action code Error code Controller code Rise of engine coolant temperature
Trouble
E02 C151NS ENG (Engine controller system)
• Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 105°C
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

and standard value
in normal state Defective engine coolant
temperature sensor system
20-426 HD465-7, HD605-7

➀
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Error code Controller code Abnormally high level in air intake temperature sensor system
Trouble
Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4.88 V.
Problem that
appears on machine
• Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Related information

Defective air intake temper- without turning starting switch ON.
1 ature sensor
IMTP (female) Resistance
(Internal trouble)
Between – 36 – 600 Ω
ness
IMTP (female)
IMTP (female)
and standard value
in normal state
ness (female) – IMTP (female) with wiring Resistance Min. 1 MΩ
3
(female) – IMTP (female) with wiring Resistance Min. 1 MΩ
harness around it
Between – 36 – 600 Ω
Circuit diagram related to air intake temperature sensor
HD465-7, HD605-7 20-427

➀
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Error code Controller code Abnormally low level in air intake temperature sensor system
Trouble
Contents of trouble • Signal voltage of air intake temperature sensor circuit is below 0.08 V.
Problem that
appears on machine

and standard value
20-428 HD465-7, HD605-7

➀
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM)
Action code Error code Controller code Abnormally high level in atmospheric pressure sensor system
Trouble
Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is above 4.78 V
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Related information

carry out troubleshooting
Defective atmospheric pres-
1 sure sensor AAPR Voltage
Between – 0.42 – 0.58 V
AAPR (female)
AAPR (female)
tor)
Possible causes AAPR (female)
Short circuit in wiring har- (female) – AAPR (female) with wiring Resistance Min. 1 MΩ
harness around it
ness
ness) (female) – AAPR (female) with wiring Resistance Min. 1 MΩ
harness around it
(female) – AAPR (female) with wiring Resistance Min. 1 MΩ
harness around it
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to atmospheric pressure sensor
HD465-7, HD605-7 20-429

➀
TROUBLESHOOTING [C222KX] , [C234NI]
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM
Action code Error code Controller code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
Problem that
appears on machine

and standard value
[C234NI] OVER-SPEED
Action code Error code Controller code Over-speed

Trouble
E02 C234NI ENG (Engine controller system)
• Engine speed sensor detected speed higher than speed set in controller.
Contents of trouble
• Criterion (for reference): Min. 2,400 rpm
Action of controller • Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine

Possible causes
and standard value 1 Defective related systems
in normal state
20-430 HD465-7, HD605-7

➀
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE
Action code Error code Controller code Abnormal voltage of fuel shut-off valve
Trouble
Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 Ω).
Action of controller • Turns off power for fuel shut-off valve.
Problem that
• Engine stops.
appears on machine

Defective fuel shut-off valve FSO (Valve side) Resistance
1
(Internal trouble)
Between (+) – (–) 23 – 40 Ω
Between (+) – chassis ground 100 kΩ
ness
FSO (wiring harness side) (+)
Possible causes tor) Wiring harness between FSO (wiring harness
and standard value side) (–) – chassis ground
in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
ness (female) – FSO (wiring harness side) (+) Resistance Min. 1 MΩ
3
(with another wiring har- with wiring harness around it
ness) Short circuit of wiring harness between FSO
(wiring harness side) (–) – chassis ground with Resistance Min. 1 MΩ
wiring harness around it
ECMA Resistance
Between – chassis ground 23 – 40 Ω
Circuit diagram related to fuel shut-off valve
HD465-7, HD605-7 20-431

➀
TROUBLESHOOTING [C259FS], [C261NS]
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE
Action code Error code Controller code Abnormality in fuel shut-off valve
Trouble
E03 C259FS ENG (Engine controller system)
Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
• Turns off power for fuel shut-off valve.
Problem that
• Engine cannot be stopped.
appears on machine

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
and standard value Clogging, looseness, break-
in normal state 3 age, or leakage of fuel filter/
leakage.
piping
4 Trouble in injector Check inside of injector directly.
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE
Action code Error code Controller code Abnormal rise of fuel temperature
Trouble
E02 C261NS ENG (Engine controller system)
• Fuel temperature sensor detected temperature lower than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 76°C
Action of controller • Limits engine speed to 800 rpm after 30 seconds.
Problem that
appears on machine

and standard value
in normal state Defective fuel temperature
sensor system
20-432 HD465-7, HD605-7

➀
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in fuel temperature sensor system
Trouble
Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Related information

Defective fuel temperature without turning starting switch ON.
1 sensor
FLTP (female) Resistance
(Internal trouble)
ness
FLTP (female)
FLTP (female)
and standard value
in normal state
ness (female) – FLTP (female) with wiring Resistance Min. 1 MΩ
3
(female) – FLTP (female) with wiring Resistance Min. 1 MΩ
harness around it
Circuit diagram related to fuel temperature sensor
HD465-7, HD605-7 20-433

➀
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in fuel temperature sensor system
Trouble
Contents of trouble • Signal voltage of fuel temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-434 HD465-7, HD605-7

➀
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR
Action code Error code Controller code Abnormal current of fuel pump actuator
Trouble
• Current of fuel pump actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Related information

Defective fuel pump actuator PUMP (male) Resistance
1
(Internal trouble)
ness
PUMP (female)
Possible causes PUMP (female)
ness (female) – PUMP (female) with wiring Resistance Min. 1 MΩ
3
(female) – PUMP (female) with wiring Resistance Min. 1 MΩ
harness around it
Between , – another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel pump actuator
HD465-7, HD605-7 20-435

➀
TROUBLESHOOTING [C318LK]
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR
Action code Error code Controller code Abnormality in fuel pump actuator
Trouble
• Displayed pressure of fuel pump is excessively different from actual value.
Contents of trouble
• Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when water temperature is 38°C)
Problem that
• Engine speed is unstable.
appears on machine

leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
3
fuel level in tank gauge is in red range, supply fuel.
Possible causes Suction resistance of fuel filter may be large. Check fuel filter directly.
and standard value Large suction resistance of
4 Negative suction pressure
in normal state fuel filter 27 kPa {203 mmHg}
(Tank side)
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
Circuit diagram related to fuel pump actuator
20-436 HD465-7, HD605-7

➀
TROUBLESHOOTING [C346KT]
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER
Action code Error code Controller code Abnormality in power-down unit of engine controller
Trouble
E03 C346KT ENG (Engine controller system)
Contents of trouble • Data recorded in power-down unit of engine controller has error.
Problem that • Power-down data (maintenance information, current controller information, engine operating hours,
appears on machine etc.) are lost.
• Charge level of battery can be checked in monitoring mode.
Related information (Code: 04301)

If fusible link is broken, circuit probably has short circuit with chassis
1 Defective fusible link (34 A)
ground.
Defective fuse
2 If fuse is broken, circuit probably has short circuit with chassis ground.
(FS1-1, FS1-4)
Disconnection in wiring har- Wiring harness between ECMB (female) –
BT2- outlet
defective contact in connec- Wiring harness between ECMA (female) , Resistance Max. 10 Ω
tor) – BT2- outlet
Wiring harness between FS1 inlet – fusible link
(FUA) – battery relay terminal B
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard value without turning starting switch ON.
in normal state
(female) – BT2- outlet with wiring har- Resistance Min. 1 MΩ
Short circuit in wiring harness around it
ness
ness) (female) , – BT2- outlet with wiring Resistance Min. 1 MΩ
harness around it
Wiring harness between FS1 inlet – fusible link
– battery relay terminal B with wiring harness Resistance Min. 1 MΩ
around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB , , –
17.3 – 34.7 V
ECMA ,
HD465-7, HD605-7 20-437

➁
TROUBLESHOOTING [C346KT]
Circuit diagram related to engine controller power supply
20-438 HD465-7, HD605-7

➀
TROUBLESHOOTING [C423L6]
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormality in in-range of timing rail pressure sensor system
Trouble
E03 C423L6 ENG (Engine controller system)
• Timing rail pressure sensor detected abnormal pressure.
Contents of trouble
• Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
• Limits high idling speed to 1,500 rpm.
Problem that
appears on machine
• Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TIMG (male) Voltage
Between – 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) –
TPR (female)
tor) TPR (female)
TPR (female)
Possible causes without turning starting switch ON.
and standard value Short circuit of wiring harness between ECMA
in normal state (female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness
ness) (female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
(female) – TPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
5 Defective engine controller ECMA (female) Resistance
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
HD465-7, HD605-7 20-439

➀
Circuit diagram related to timing rail pressure sensor
20-440 HD465-7, HD605-7

➀
[C431L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM: SEE

SEPARATE LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE
SENSED)
Action code Error code Controller code Abnormality in idling validation switch system: See separate
Trouble
E01 C431L4 ENG list (L4) (Both signal voltages of 2 systems are sensed)
Contents of trouble • Both idling validation switch signals 2 and 3 are open (above 4.5 V).
Action of controller • (The controller displays action code E03, CHECK/REPAIR.)
Problem that • None in particular. (Since the controller controls according to the throttle sensor signal (potentiometer),
appears on machine no problems appear in the truck body.
Related information

2) Disconnect connector AS1.
Release the accelerator
Between AS1 Resistance Max. 100 Ω
pedal "Idling ON".
Idling validation switch de- (male) and
1 Press the accelerator pedal
fective Resistance Min. 1 MΩ
"Idling OFF".
Between AS0 Resistance Min. 1 MΩ
pedal "Idling ON".
(male) and
Press the accelerator pedal
"Idling OFF".
2) Disconnect connectors ECMB and AS1.
Disconnection in wiring har- Wiring harness between ECMB (female)
2 and AS1 (female)
and AS1 (female)
Possible causes
and standard value Wiring harness between ECMB (female)
in normal state and AS1 (female)
Resistance value between
Wiring harness between
ECMB (female) , AS1 (fe-
ECMB (female) and AS1 Min. 1 M Ω
male) and chassis
(female)
ground
ECMB (female) and AS1 Min. 1 MΩ
male) and chassis
(female)
ground
male) and chassis
(female)
ground
1) Connect the all connectors.
4 Engine controller defective 3) Press the accelerator pedal 3 times repeatedly.
HD465-7, HD605-7 20-441

➀
Circuit diagram related to engine idling validation switch
20-442 HD465-7, HD605-7

➀
[C432L5] ERROR IN IDLING VALIDATION PROCESS ( SEE SEPARATE LIST (L5))
Action code Error code Controller code Error in idling validation process: See separate list (L5)
Trouble (Potentiometer signal and switch signal do not agree with each
E03 C432L5 ENG other)
• The throttle potentiometer signal of the accelerator pedal is not conformed to idling validation switch
Contents of trouble
signal 2.
• The throttle is conformed to the idling validation switch (In idling: 0%, Off idling: 35%).
• If this failure is detected when the throttle sensor signal is on the low speed side (idling side), the throt-
tle is conformed to the throttle sensor.
Problem that
• The engine speed is kept at low idling or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

pedal "Idling ON".
"Idling OFF".
pedal "Idling ON".
(male) and
"Idling OFF".
2 and AS1 (female)
and AS1 (female)
Possible causes and AS1 (female)
and standard value 1) Turn the starting switch OFF.
in normal state 2) Disconnect connectors ECMB and AS1.
male) and chassis
(female)
ground
male) and chassis
(female)
ground
male) and chassis
(female)
ground
4) Connect connector.
4 Slottle sensor defective 5) Startin switch ON.
Between Release the accelerator
Voltage 0.35 – 0.55V
AS1 pedal "Idling ON".
(male) Press the accelerator pedal
Voltage 3.55 – 3.75V
and "Idling OFF".
HD465-7, HD605-7 20-443

➀

Possible causes
and standard value
in normal state
Circuit diagram related to engine idling validation process
20-444 HD465-7, HD605-7

➀
TROUBLESHOOTING [C441KK], [C442KG]
[C441KK] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Error code Controller code Abnormally low level in battery voltage system
Trouble
E01 C441KK ENG (Engine controller system)
Contents of trouble • Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for error code [C346KT].
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Error code Controller code Abnormally low level in battery voltage system
Trouble
E01 C442KG ENG (Engine controller system)
Contents of trouble • Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for error code [C346KT].
HD465-7, HD605-7 20-445

➀
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
• Opens and controls fuel rail.
Problem that
appears on machine
• Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between – 0.42 – 0.58 V
RPR (female)
tor) RPR (female)
Possible causes RPR (female)
Short circuit in wiring har- (female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
ness
ness) (female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
(female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to fuel rail pressure sensor
20-446 HD465-7, HD605-7

➀
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in fuel rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
• Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine

and standard value
HD465-7, HD605-7 20-447

➀
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR
Action code Error code Controller code Abnormal current of fuel rail actuator
Trouble
• Current of fuel rail actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Related information
• Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance
1
(Internal trouble)
ness
RAIL (female)
RAIL (female)
Possible causes
ness (female) – RAIL (female) with wiring har- Resistance Min. 1 MΩ
3
(with another wiring harness around it
(female) – RAIL (female) with wiring har- Resistance Min. 1 MΩ
ness around it
Between , – another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel rail actuator
20-448 HD465-7, HD605-7

➀
TROUBLESHOOTING [C467LK], [C468LK]
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL
Action code Error code Controller code Abnormality in timing rail actuator control
Trouble
• Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot
Contents of trouble
be obtained.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for error code [C112LK].
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL
Action code Error code Controller code Abnormality in fuel rail actuator control
Trouble
• Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
Contents of trouble
obtained.
• Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

Possible causes leakage.
piping
and standard value
3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
in normal state
Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
HD465-7, HD605-7 20-449

➀
TROUBLESHOOTING [C514LK]
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR
Action code Error code Controller code Abnormality in fuel rail actuator
Trouble
• Displayed injection rate of fuel rail is excessively different from actual injection rate.
Contents of trouble
• Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.
• Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for error code [C468LK].
20-450 HD465-7, HD605-7

➀
[C551L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM: SEE SEPA-

RATE LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT
SENSED)
Action code Error code Controller code Abnormality in idling validation switch system: See separate
Trouble
E01 C551L4 ENG list (L4) (Either signal voltage of 2 systems is not sensed)
Contents of trouble • Both of idle validation switch signals 2 and 3 are closed (connected to GND).
• The controller sets the engine speed to low idling.
Problem that
• The engine speed is kept at low idling.
appears on machine
Related information

pedal "Idling ON".
"Idling OFF".
pedal "Idling ON".
(male) and
"Idling OFF".
2 and AS1 (female)
and AS1 (female)
Possible causes
and standard value Wiring harness between ECMB (female)
in normal state and AS1 (female)
male) and chassis
(female)
ground
male) and chassis
(female)
ground
male) and chassis
(female)
ground
HD465-7, HD605-7 20-451

➀
Circuit diagram related to idling validation switch
20-452 HD465-7, HD605-7

➀
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormality in in-range of fuel rail pressure sensor system
Trouble
E03 C554L6 ENG (Engine controller system)
• Fuel rail pressure sensor detected abnormal pressure.
Contents of trouble
• Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
• Limits maximum injection rate to 270 mm3/st
Problem that
appears on machine
• Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between – 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) –
RPR (female)
tor) RPR (female)
RPR (female)
Possible causes without turning starting switch ON.
and standard value Short circuit of wiring harness between ECMA
in normal state (female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness
ness) (female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
(female) – RPR (female) with wiring har- Resistance Min. 1 MΩ
ness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
HD465-7, HD605-7 20-453

➀
Circuit diagram related to fuel rail pressure sensor
20-454 HD465-7, HD605-7

➀
TROUBLESHOOTING ENG-1
ENG-1 ENGINE DOES NOT START

Trouble Engine does not start
Not set Not set ENG
Contents of trouble • Engine does not start.
Action of controller • None in particular.
Problem that
• Engine does not start.
appears on machine
• If any error code related to the engine controller or transmission controller is indicated, perform trou-
Related information
bleshooting for it first.

Specific gravity Min. 1.26
1 Battery defective
Voltage Min. 25 V
2) Replace R01 with normal one.
When engine starting relay (R01) No Relay (R01) normal
is replaced, is failure repaired? Yes Relay (R01) defective
2) Disconnect connector R01.
3) Check R01.
Engine starting relay (R01)
2
defective Between R01 (male) and Resistance 200 – 400 Ω
3) Check R01.
4) Apply voltage between R01 (male) and .
Apply 24 V between
Resistance Min. 1 MΩ
Between R01 (male) and .
and Do not apply voltage
between and .
Possible causes
in normal state 2) Replace R02 with normal one.
When transmission neutral relay No Relay (R02) normal
(R02) is replaced, is failure repaired? Yes Relay (R02) defective
3) Check R02.
Transmission neutral relay
3
(R02) defective Between R02 (male) and Resistance 200 – 400 Ω
3) Check R02.
Apply 24 V between
between and .
2) Replace diode (D01).
4 Diode (D01) defective 3) Turn the starting switch to the START position.
Failure is not repaired. Diode (D01) is normal.
Failure is repaired. Diode (D01) is defective.
HD465-7, HD605-7 20-455

➀

Wiring harness between bat- Voltage between battery ter-
tery and battery terminal 01 minal 01 (B), 03 (B), 02 (M),
20 – 30 V
(B), 03 (B), 02 (M), and 04 and 04 (M) and machine
(M) body
Disconnection of wiring har- 2) Disconnect fuse BT3 terminal and battery relay terminal 02 (M)
5 ness between battery relay and 04 (M).
and related wiring harness Wiring harness between bat- Resistance value between
tery relay terminal 02 (M), 04 battery relay terminal 02 (M), Max. 1 Ω
(M) and fuse BT3 04 (M) and fuse BT3
2) Disconnect the negative (-) terminal of the battery relay.
Wiring harness between the negative (-) termi-
nal of the battery relay and machine body
1) Turn the starting switch to the START position.
Disconnection in wiring har- Wiring harness between bat-
6 ness related to starting mo- tery relay terminal 02 (M), 04 Voltage between starting
tor terminal B motor terminal B and ma- 20 – 30 V
(M) and starting motor termi-
chine body
nal B
Failure is repaired. Diode (D01) is normal.
Possible causes Failure is not repaired. Diode (D01) is defective.
and standard value
in normal state
2) Disconnect connector ATC3B, diode (D01), alternator terminal R,
and starting motor terminal R.
Short circuit with power 3) Turn the starting switch ON.
8 source in wiring harness of
starting motor terminal R Wiring harness between di- Voltage between diode
ode (D01), starting motor (D01), starting motor termi-
Max. 12 V
terminal R, and alternator nal R (on the harness side),
terminal R and machine body
Alternator (Regulator) defec-
9 Voltage between starting motor terminal R and machine
tive Max. 12 V
body
Failure is not repaired. Diode (D08) is normal.
2) Disconnect connector R01, battery relay terminal 14 (BR), 12 (BR),
and starting switch terminals BR and C.
Wiring harness between Resistance value between
ness
starting switch terminal B starting switch terminal B
(Disconnection or defective Max. 1 Ω
11 and battery relay terminals and battery relay terminal 01
contact)
01 (B) and 03 (B). (B) and 03 (B)
• Wiring harness related to
starting switch Wiring harness between Resistance value between
starting switch terminal BR starting switch terminal BR
Max. 1 Ω
and battery relay terminal 14 and battery relay terminal 14
(BR), 12 (BR) (BR), 12 (BR)
20-456 HD465-7, HD605-7

➀
Possible causes
and standard value Cause Standard value in normal state/Remarks on troubleshooting
in normal state
Disconnection in wiring har- ★ Measure at starting switch terminal BR (+ side of tester) with a tester
ness in the diode range.
11 Wiring harness between Resistance value between
contact)
• Wiring harness related to starting switch terminal C starting switch terminal C Max. 1 Ω
starting switch and R01 (female) and R01 (female)
2) Disconnect connectors R01 and R02, fuse BT3 terminal , and
starting motor terminal S.
Disconnection in wiring har- Wiring harness between Resistance value between
ness fuse BT3 terminal and fuse BT3 terminal and Max. 1 Ω
(Disconnection or defective R01 (female) R01 (female)
12
contact)
• Wiring harness related to Wiring harness between Resistance value between
engine starting relay (R01) R01 (female) and R02 R01 (female) and R02 Max. 1 Ω
(female) (female)
Possible causes R01 (female) and starting R01 (female) and starting Max. 1 Ω
and standard value motor terminal S motor terminal S
in normal state
Disconnection in wiring har- 2) Disconnect connector R02 and S2 (connector of shift lever side).
(Disconnection or defective Wiring harness between Resistance value between
13 contact) R02 (female) and S2 (fe- R02 (female) and S2 (fe- Max. 1 Ω
• Wiring harness related to male) male)
transmission neutral relay Wiring harness between Resistance value between
(R02) R02 (female) , and R02 (female) , and Max. 1 Ω
chassis ground chassis ground
1) Disconnect the starting switch terminals.
2) Check the starting switch.
14 Starting switch defective
Turn the starting switch to Resistance value between
Max. 1 Ω
the START position. terminals B and C
1) Check the starting motor.
15 Starting motor defective • If the check result of the starting motor is normal, the starting motor
is normal.
HD465-7, HD605-7 20-457

➀
Circuit diagram related to engine does not start
20-458 HD465-7, HD605-7

➀
ENG-2 FAILURE IN PREHEATING

a) Engine is not preheated
Action code Error code Controller code 1. Failure in preheating

Trouble
Not set Not set ENG a) Engine is not preheated
Contents of trouble • The engine is not preheated. (Engine cooling water temperature is below 0°C.)
Problem that
• The engine is not preheated.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12A and opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
tive Resistance Min. 1M Ω
OFF
Between E11B and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12B and opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the heater terminal.
Intake air heater (Ribbon 3) Check the heater.
2
heater) defective
Between heater terminal and chassis
Resistance 0.17 – 0.27 Ω
ground
Possible causes 1) Turn the starting switch OFF.
and standard value 2) Replace R37 with a normal relay.
in normal state 3) Turn the starting switch ON.
When the automatic preheater re- No Relay (R37) is normal.
lay (R37) is replaced, is failure re- Relay (R37) is defec-
paired? Yes
tive.
Automatic preheater relay 3) Check connector R37.
3
3) Check connector R37.
Apply 24 V between
Resistance Min. 1M Ω
between and .
Diode (E17A, E17B) defec- 2) Replace diode (E17A, E17B).
4
tive Failure is not repaired. Diode (D01) is normal.
HD465-7, HD605-7 20-459

➀

2) Disconnect connectors ECMA, R37, E11A, E11B, E12A, E12B, and
fuse BT4 terminal (4).
Wiring harness between Resistance value ECMA (fe-
ECMA (female) – R37 male) and R37 (female) Max. 1 Ω
(female)
Disconnection in wiring har- R37 (female) and chassis R37 (female) and chassis Max. 1 Ω
ness ground ground
5
contact) Wiring harness between Resistance value between
R37 (female) and E11A, R37 (female) and E11A, Max. 1 Ω
E11B E11B
Possible causes Wiring harness between Resistance value between

and standard value fuse BT4 terminal and fuse BT4 terminal and Max. 1 Ω
in normal state R37 (female) R37 (female)
Wiring harness between bat- Resistance value between
tery relay terminal 02 (M), 04 battery relay terminal 02 (M), Max. 1 Ω
(M) and E12A, E12B 04 (M) and E12A, E12B
2) Disconnect connector ECMB.
4) Connect the connector.
6) Engine water temperature: Max. 0°C
In 30 seconds after starting switch
is turned ON (During preheating Voltage 20 – 30V
Between time)
ECMA
and , 30 seconds or more after starting
switch is turned ON (After preheat- Voltage Max. 1 V
ing time)
20-460 HD465-7, HD605-7

➀
Circuit diagram related to preheating
HD465-7, HD605-7 20-461

➀
b) Preheating is actuated even under non-actuation conditions for preheating
Action code Error code Controller code Failure in preheating

Trouble b) Preheating is actuated even under non-actuation conditions
Not set Not set ENG for preheating
Contents of trouble • Preheating is actuated even under non-actuation conditions for preheating.
Problem that
• Preheating is actuated even under non-actuation conditions for preheating.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12A and opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
tive Resistance Min. 1 MΩ
OFF
Between E11B and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12B and opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the connector.
Possible causes Wiring harness between Voltage between ECMA (fe-
and standard value ECMA (female) and R37 male) , R37 (female) Max. 1 V
in normal state Short circuit with power (female) and chassis ground
2
source in wiring harness Wiring harness between Voltage between R37 (fe-
R37 (female) and E11A, male) , E11A, E11B and Max. 1 V
E11B chassis ground
Wiring harness between Voltage between AC5A (fe-
AC5A (female) and HES male) , HES and chassis Max. 1 V
(★) ground
Measure only on E12A side for wiring harness marked with (★).
6) Engine water temperature: Max. 0 °C
In __ seconds after starting switch
is turned ON (During preheating Voltage 20 – 30V
Between time)
ECMA
and , __ seconds or more after starting
switch is turned ON (After preheat- Voltage Max. 1 V
ing time)
20-462 HD465-7, HD605-7

➁
Circuit diagram related to preheating time
HD465-7, HD605-7 20-463

➀
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY

a) When AISS switch is set in AUTO, LOW SPEED control is selected
Action code Error code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set a) When AISS switch is set in AUTO, LOW SPEED control is se-
lected
Contents of trouble • When AISS switch is set in AUTO, LOW SPEED control is selected
Problem that
• When AISS switch is set in AUTO, LOW SPEED control is selected
appears on machine
Related information • Error code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 Ω
(male) and
Set the AISS switch in LOW. Resistance Min. 1 MΩ
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Between R07 (male) and Resistance 200 – 400 Ω
Possible causes 3) Check the relay.
and standard value 4) Apply voltage between R07 (male) and .
in normal state Apply 24 V between and
Between R07 Resistance Min. 1 MΩ
.
(male) and
Do not apply 24 V between
and .
2) Disconnect connectors AISS, R07, and fuse BT2 terminal .
Disconnection in wiring har- Wiring harness between fuse BT2 and
3 AISS (female)
Wiring harness between AISS (female) and
R07 (female)
Wiring harness between R07 (female) and
chassis ground
4 Engine controller defective 5) Turn the starting switch ON.
Between ECMB Set the AISS switch in Voltage 20 – 30 V
and chassis AUTO.
ground Set the AISS switch in LOW. Voltage Max. 1 V
20-464 HD465-7, HD605-7

➀
b) When AISS switch is set in LOW SPEED, AUTO control is selected
Action code Error code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set b) When AISS switch is set in LOW SPEED, AUTO control is se-
lected
Contents of trouble • When AISS switch is set in LOW SPEED, AUTO control is selected
Problem that
• When AISS switch is set in LOW SPEED, AUTO control is selected
appears on machine
Related information • Error code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 Ω
(male) and
Set the AISS switch in LOW Resistance Min. 1 MΩ
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Possible causes 2) Disconnect connector R07.
and standard value 3) Check the relay.
in normal state 4) Apply voltage between R07 (male) and .
Apply 24 V between and
Between R07 Resistance Min. 1 MΩ
.
(male) and
Do not apply 24 V between
and .
Disconnection in wiring har- 2) Disconnect connector R07.
3
chassis ground
2) Disconnect connectors AISS and R07.
Wiring harness be- Wiring harness be-
tween AISS (female) tween AISS (female)
Short circuit with power Voltage Max. 1 V
4 and R07 (female) , R07 (female)
source in wiring harness
and chassis ground
Wiring harness be- Wiring harness be-
tween ECMB (female) tween ECMB (female)
Voltage Max. 1 V
and R07 (female) , R07 (female)
and chassis ground
HD465-7, HD605-7 20-465

➀

Possible causes 3) Insert T-adapter.
and standard value 4) Connect the connector.
in normal state 5 Engine controller defective 5) Turn the starting switch ON.
Between ECMB Set the AISS switch in Voltage 20 – 30 V
and chassis AUTO.
ground Set the AISS switch in LOW. Voltage Max. 1 V
Circuit diagram related to low speed, auto control
20-466 HD465-7, HD605-7

➀
TROUBLESHOOTING FOR TRANSMISSION
CONTROLLER SYSTEM
(TM MODE)
Electrical system diagram related to transmission control .......................................................................... 20-503

Information in troubleshooting table ....................................................................................................... 20-504
Trouble code table ................................................................................................................................. 20-505
[1380MW] Lockup clutch • Slip (MW).................................................................................................. 20-506
[1500L0] Detection of double engagement • See separate list (L0) ............................................. 20-507
[15B0NX] Clogging of transmission oil filter • Clogging (NX) ............................................................. 20-508
[15E0KM] R o F gear shift abuse 1 • Mistake in operation or setting (KM) ....................................... 20-509
[15E7KM] R o F gear shift abuse 2 • Mistake in operation or setting (KM) ........................................ 20-509
[15G0MW] R clutch • Slip (MW)........................................................................................................... 20-510
[15H0MW] Hi clutch • Slip (MW).......................................................................................................... 20-511
[15J0MW] Lo clutch • Slip (MW) .......................................................................................................... 20-513
[15K0MW] 1st clutch • Slip (MW) ........................................................................................................ 20-515
[15L0MW] 2nd clutch • Slip (MW) ....................................................................................................... 20-516
[15M0MW] 3rd clutch • Slip (MW) ........................................................................................................ 20-517
[15N0MW] 4th clutch • Slip (MW) ........................................................................................................ 20-518
[15SBL1] R clutch solenoid • See separate list (L1)...................................................................... 20-519
[15SBMA] R clutch solenoid • Malfunction (MA)................................................................................. 20-520
[15SCL1] Hi clutch solenoid • See separate list (L1)..................................................................... 20-521
[15SCMA] Hi clutch solenoid • Malfunction (MA) ................................................................................ 20-522
[15SDL1] Lo clutch solenoid • Seee separate list (L1) .................................................................. 20-523
[15SDMA] Lo clutch solenoid • Malfunction (MA) ............................................................................... 20-524
[15SEL1] 1st clutch solenoid • See separate list (L1) ................................................................... 20-525
[15SEMA] 1st clutch solenoid • Malfunction (MA)............................................................................... 20-526
[15SFL1] 2nd clutch solenoid • See separate list (L1) .................................................................. 20-527
[15SFMA] 2nd clutch solenoid • Malfunction (MA) ............................................................................. 20-528
[15SGL1] 3rd clutch solenoid • See separate list (L1) ................................................................... 20-529
[15SGMA] 3rd clutch solenoid • Malfunction (MA) .............................................................................. 20-530
[15SHL1] 4th clutch solenoid • See separate list (L1) ...................................................................... 20-531
[15SHMA] 4th clutch solenoid • Malfunction (MA) .............................................................................. 20-532
[15SJL1] Lockup clutch solenoid • 15SJ (L1) ................................................................................... 20-533
[15SJMA] Lockup clutch solenoid • 15SJ (MA) .................................................................................. 20-534
[2F00KM] Parking brake • Mistake in operation or setting (KM) ........................................................ 20-535
[989A00] Engine overrun prevention command signal • Operation (00)........................................... 20-537
[989AKZ] Engine overrun prevention command signal • Disconnection or short circuit (KZ)............ 20-538
[AA10NX] Air cleaner element • Clogging (NX).................................................................................. 20-539
[AB00MA] Alternator • Malfunction (MA)............................................................................................. 20-541
[B@BCZK] Lowering of radiator water • Lowering of level (ZK)........................................................... 20-543
[D1BOKZ] Transmission controller cutout .......................................................................................... 20-544
[D5ZMKZ] Disconnection, grounding fault, or short circuit in engine output mode command line •
Disconnection or short circuit (KZ) .................................................................................... 20-546
[DAQ0KK] Transmission controller • Lowering of source/input voltage (KK) ...................................... 20-547
[DAQ1KK] Main power line of transmission controller • Lowering of source/input voltage (KK) ......... 20-549
[DAQ2KK] Transmission controller load power line • Lowering of source/input voltage (KK) ............ 20-551
[DAQ3KK] Direct line of transmission controller battery • Lowering of source/input voltage (KK) ...... 20-553
[DAQ9KM] Transmission controller wiring harness • Mistake in operation or setting (KM) ................. 20-554
[DAQ9KQ] Transmission controller wiring harness • Disagreement of model selection signals (KQ) . 20-555
[DAQAKQ] Transmission controller rotary switch • Disagreement of model selection signals (KQ) .... 20-556
[DAQSMA] Transmission controller • Malfunction (MA) ....................................................................... 20-556
HD465-7, HD605-7 20-501

(7)
TROUBLESHOOTING REAR SUSPENSION CYLINDER
[DDTGKA] Lockup clutch fill switch: Disconnection (KA) .................................................................... 20-557

[DDTHKA] Hi clutch fill switch: Disconnection (KA)............................................................................. 20-558
[DDTJKA] Lo clutch fill switch: Disconnection (KA) ............................................................................ 20-559
[DDTKKA] 1st clutch fill switch: Disconnection (KA) ........................................................................... 20-560
[DDTLKA] 2nd clutch fill switch: Disconnection (KA) .......................................................................... 20-561
[DDTMKA] 3rd clutch fill switch: Disconnection (KA)........................................................................... 20-562
[DDTNKA] R clutch fill switch: Disconnection (KA) ............................................................................. 20-563
[DDTPKA] 4th clutch fill switch: Disconnection (KA) ........................................................................... 20-564
[DF10KA] Shift lever: Disconnection (KA) .......................................................................................... 20-565
[DF10KB] Shift lever: Short circuit (KB) ............................................................................................. 20-569
[DGF1KX] Transmission valve oil temperature sensor: Out of input signal range (KX) ...................... 20-572
[DGT1KX] Torque converter oil temperature sensor: Out of inputsignal range (KX) .......................... 20-574
[DHT5KX] Torque converter oil pressure sensor: Out of input signal range (KX) .............................. 20-575
[DHT5L6] Torque converter oil pressure sensor: See separate list (L6) ........................................... 20-577
[DJF1KA] Fuel level sensor: Disconnection (KA) ............................................................................... 20-578
[DK11KX] Throttle angle sensor: Out of input signal range (KX) ....................................................... 20-579
[DLE2KA] Engine speed sensor: Disconnection (KA) ........................................................................ 20-581
[DLE2LC] Engine speed sensor: See separate list (LC) ................................................................ 20-582
[DLF1KA] Transmission input shaft speed sensor: Disconnection (KA) ............................................ 20-583
[DLF1LC] Transmission input shaft speed sensor: See separate list (LC) .................................... 20-584
[DLF2KA] Transmission intermediate shaft speed sensor: Disconnection (KA) ................................ 20-585
[DLF2LC] Transmission intermediate shaft speed sensor: See separate list (LC) ....................... 20-586
[DLT3KA] Transmission output shaft speed sensor: Disconnection (KA) .......................................... 20-587
[DLT3LC] Transmission output shaft speed sensor: See separate list (LC) .................................. 20-588
[DXH1KA] Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA) .................. 20-590
[DXH1KB] Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB) ......................... 20-591
[DXH2KA] Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA) ......................... 20-592
[DXH2KB] Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB) ............................... 20-593
[DXH3KA] Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA) ........................ 20-595
[DXH3KB] Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB) ............................... 20-596
[DXH4KA] Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA) ....................... 20-598
[DXH4KB] Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB) ............................... 20-599
[DXH5KA] Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA) ...................... 20-600
[DXH5KB] Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB) ............................. 20-601
[DXH6KA] Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA) ....................... 20-602
[DXH6KB] Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB) .............................. 20-603
[DXH7KA] Disconnection in output circuit of R clutch solenoid: Disconnection (KA) .......................... 20-604
[DXH7KB] Short circuit in output circuit of R clutch solenoid: Short circuit (KB) ................................. 20-605
[DXHHKA] Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA) ....................... 20-606
[DXHHKB] Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB) .............................. 20-607
TM-1 Fuel level gauge does not operate normally (It always indicates "FULL") ........................ 20-608
TM-2 Abnormality in backup lamp and backup buzzer ............................................................... 20-609
a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer
are not turned ON.......................................................................................................... 20-609
b) Backup lamp is not turned ON (Backup buzzer is normal)............................................ 20-610
c) Backup buzzer is not turned ON (Backup lamp is normal) ........................................... 20-610
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON ...... 20-611
20-502 HD465-7, HD605-7

!
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

★ For details of this page, see page 90-19.
HD465-7, HD605-7 20-503

➁


panel panel panel
Problem that
appears on machine

1
• Disconnection
• Short circuit
3
side.
side.
5
side.
20-504 HD465-7, HD605-7

➀
TROUBLESHOOTING TROUBLE CODE TABLE

TROUBLE CODE TABLE

a Regarding trouble code provided with instruction "Refer to table", check it against table below.
Fill signals at two or more channels which are not set as combi-
KA Disconnection in wiring L0 nation are turned ON at the same time.
Source voltage reduction/
KK input L2 Fuel pressure is above maxim specified value.
Type select signal incon-

KQ sistency L3 Object part is uncontrollable.

Disconnection or short cir-
KZ cuit LC rpm signals in two systems are inconsistent.

MW Sliding
NS Overheat
HD465-7, HD605-7 20-505

#
TROUBLESHOOTING [1380MW]
[1380MW] LOCKUP CLUTCH • SLIP (MW)
Action code Error code Controller code Lockup clutch • Slip (MW)
Trouble (Command is Holding pressure, fill switch is ON, and slip is
E03 1380MW TM sensed)
• When a signal is output to the lockup clutch ECMV, the value calculated from the signals of the engine
Contents of trouble speed sensor, transmission input shaft speed sensor, transmission intermediate shaft speed sensor,
and transmission output shaft speed sensor is abnormal.
• The controller keeps the current gear speed and turns the lockup operation OFF.
• If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that • The lockup operation is reset and the gear cannot be shifted.
appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
• This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).
Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

2) Disconnect connector CN20.
Lockup clutch ECMV defec- 3) Connect T-adapter.
1
tive Between CN20 (male) and Resistance 5 – 15 z
Between CN20 (male) , and chassis
Resistance Min. 1 Mz
ground
2) Disconnect connector ATC2 and CN10.
Disconnection in wiring har- 3) Connect T-adapter.
Possible causes
ness
and standard value 2 Wiring harness between ATC2 (female) and
(Disconnection or defective Resistance Max. 1 z
in normal state CN20 (female)
contact)
Wiring harness between ATC2 (female) and
Resistance Max. 1 z
CN20 (female)
Defective sensing by speed
3 • Troubleshooting by the error codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC2.
Transmission controller de- 3) Connect T-adapter.
4
fective
Wiring harness between ATC2 (female)
Resistance 5 – 15 z
and ATC2 (female)
20-506 HD465-7, HD605-7

(7)
TROUBLESHOOTING [1500L0]
[1500L0] DETECTION OF DOUBLE ENGAGEMENT • SEE SEPARATE LIST (L0)

Trouble Detection of double engagement • See separate list (L0)
E03 1500L0 TM
Contents of trouble • The fill switch signals of abnormally combined 2 clutches are input.
Action of controller • The gear is set in Neutral during travel and the machine cannot start again.
Problem that • The transmission cutout relay is turned OFF.
appears on machine • The gear is set in Neutral.
• Another failure (Clutch pressure control valve system error code: 15S*L1) occurs simultaneously with
Related information
this failure.

Clutch pressure control
Possible causes
1 valve system error code • Perform troubleshooting by the indicated error code.
and standard value
(15S*L1) is indicated.
in normal state
Transmission controller de-
2 • Perform troubleshooting by the indicated error code.
fective
HD465-7, HD605-7 20-507

#
TROUBLESHOOTING [15B0NX]
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER • CLOGGING (NX)

Trouble Clogging of transmission oil filter • Clogging (NX)
E01 15B0NX TM
• When the torque converter oil temperature is above 50°C, the signal circuit of the transmission clogging
Contents of trouble
sensor is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, dust may enter the transmission circuit.
appears on machine
• This failure can be checked in the monitoring function (Code: 33300).
Related information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Clogging of transmission fil-
1 • Clean or replace.
ter
2) Disconnect connectors ATC5A and CN10.
Transmission filter clogging 3) Connect T-adapter.
2
sensor defective
Between TMF (male) Filter is normal. Resistance Max. 1 z
and Filter is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC5A, TNF, and CN-10.
Possible causes Disconnection in wiring har- 3) Connect T-adapter.
and standard value ness
3 Wiring harness between ATC5A (female)
in normal state (Disconnection or defective Resistance Max. 1 z
and TMF (female)
contact)
Wiring harness between CJH1 (female)
Resistance Max. 1 z
and TMF (female)
2) Disconnect connectors ATC5A and ATC3A.
Transmission controller de- 4) Connect conector.
4
Between ATC5A Filter is normal. Voltage Max. 1 V
and chassis ground Filter is clogged. Voltage 20 – 30 V
20-508 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15E0KM], [15E7KM]
[15E0KM] R $ F GEAR SHIFT ABUSE 1 • MISTAKE IN OPERATION OR SETTING (KM)

Trouble R $ F gear shift abuse 1 • Mistake in operation or setting (KM)
Not set 15E0KM TM
• When the output shaft speed is 200 rpm – 300 rpm (approx. 5 – 7 km/h), the gear is shifted from reverse
Contents of trouble
to forward.
Problem that • If the machine is used without repairing, it may be broken.
appears on machine • The failure is only recorded in the failure history.
Related information • This failure can be checked in the monitoring function (Code: 31400).

and standard value
in normal state 1 Abuse • Change the travel direction after the machine is stopped perfectly.
[15E7KM] R $ F GEAR SHIFT ABUSE 2 • MISTAKE IN OPERATION OR SETTING (KM)

Trouble R $ F gear shift abuse 2 • Mistake in operation or setting (KM)
15E7KM TM
• When the output shaft speed is above 300 rpm (approx. 7 km/h), the gear is shifted from reverse to
Contents of trouble
forward.
Problem that • If the machine is used without repairing, it may be broken.
appears on machine • The failure is only recorded in the failure history.

and standard value
in normal state 1 Abuse • Change the travel direction after the machine is stopped perfectly.
HD465-7, HD605-7 20-509

#
TROUBLESHOOTING [15G0MW]
[15G0MW] R CLUTCH • SLIP (MW)
Action code Error code Controller code R clutch • Slip (MW)

E03 15G0MW TM sensed)
• When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission
Contents of trouble input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Action of controller • The controller sets the gear in Neutral.
Problem that
• The gear is set in Neutral suddenly during travel and the machine cannot start again.
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure
control valve for a defect.

1 R clutch ECMV defective
Between CN10 (male) and Resistance 5 – 15 z
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-510 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15H0MW]
[15H0MW] HI CLUTCH • SLIP (MW)
Action code Error code Controller code Hi clutch • Slip (MW)

E03 15H0MW TM sensed)
• When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission
Problem that
• The gear is set in Neutral suddenly during travel.
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

1 Hi clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN18 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-511

(7)
TROUBLESHOOTING [15H0MW]
20-512 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15J0MW]
[15J0MW] LO CLUTCH • SLIP (MW)
Action code Error code Controller code Lo clutch • Slip (MW)

E03 15J0MW TM sensed)
• When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the transmission
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

1 Lo clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN16 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-513

(7)
TROUBLESHOOTING [15J0MW]
20-514 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15K0MW]
[15K0MW] 1ST CLUTCH • SLIP (MW)
Action code Error code Controller code 1st clutch • Slip (MW)
E03 15K0MW TM sensed)
• When a signal is output to the 1st clutch ECMV, the value calculated from the signals of the transmis-
Contents of trouble sion input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output
shaft speed sensor is abnormal.
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

1 1st clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN6 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-515

(7)
TROUBLESHOOTING [15L0MW]
[15L0MW] 2ND CLUTCH • SLIP (MW)
Action code Error code Controller code 2nd clutch • Slip (MW)
E03 15L0MW TM sensed)
• When a signal is output to the 2nd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

1 2nd clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-516 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15M0MW]
[15M0MW] 3RD CLUTCH • SLIP (MW)
Action code Error code Controller code 3rd clutch • Slip (MW)
E03 15M0MW TM sensed)
• When a signal is output to the 3rd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

1 3rd clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN12 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-517

(7)
TROUBLESHOOTING [15N0MW]
[15N0MW] 4TH CLUTCH • SLIP (MW)
Action code Error code Controller code 4th clutch • Slip (MW)
E03 15N0MW TM sensed)
• When a signal is output to the 4th clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

1 4th clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-518 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SBL1]
[15SBL1] R CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code R clutch solenoid • See separate list (L1)
Trouble
E03 15SBL1 TM (Command is OFF and fill switch is ON)
• When the output to the R clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
clutch is not disengaged.
Problem that
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).

1 R clutch fill switch defective When dis-
Between CN11 (male) and engaged
chassis ground When en-
Resistance Max. 1 z
gaged
Possible causes
and standard value Grounding fault in wiring
in normal state 2 Resistance value be-
harness
Wiring harness between ATC5A tween ATC5A (female)
Min. 1 Mz
(female) and CN11 (female) , CN11 (female)
and chassis ground
3 When dis-
fective Resistance Min. 1 Mz
Between ATC5A (female) and engaged
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-519

(7)
TROUBLESHOOTING [15SBMA]
[15SBMA] R CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code R clutch solenoid • Malfunction (MA)
E03 15SBMA TM sensed)
• When a signal is output to the R clutch ECMV, the signal from the fill switch is kept OFF and the value
Contents of trouble calculated from the signals of the transmission input shaft speed sensor, transmission intermediate
shaft speed sensor, and transmission output shaft speed sensor is abnormal.
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-520 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SCL1]
[15SCL1] HI CLUTCH SOLENOID • SEE SEPARATE LIST (L1)

Action code Error code Controller code Hi clutch solenoid • See separate list (L1)
Trouble
E03 15SCL1 TM (Command is OFF and fill switch is ON)
• When the output to the Hi clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Hi clutch fill switch defective When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-521

(7)
TROUBLESHOOTING [15SCMA]
[15SCMA] HI CLUTCH SOLENOID • MALFUNCTION (MA)

Action code Error code Controller code Hi clutch solenoid • Malfunction (MA)
E03 15SCMA TM sensed)
• When a signal is output to the Hi clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN18 (female)
sensor
4
fective
and ATC2 (female)
20-522 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SDL1]
[15SDL1] LO CLUTCH SOLENOID • SEE SEPARATE LIST (L1)

Action code Error code Controller code Lo clutch solenoid • See separate list (L1)
Trouble
E03 15SDL1 TM (Command is OFF and fill switch is ON)
• When the output to the Lo clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Lo clutch fill switch defective When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-523

(7)
TROUBLESHOOTING [15SDMA]
[15SDMA] LO CLUTCH SOLENOID • MALFUNCTION (MA)

Action code Error code Controller code Lo clutch solenoid • Malfunction (MA)
E03 15SDMA TM sensed)
• When a signal is output to the Lo clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN16 (female)
sensor
4
fective
and ATC2 (female)
20-524 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SEL1]
[15SEL1] 1ST CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 1st clutch solenoid • See separate list (L1)
Trouble
E03 15SEL1 TM (Command is OFF and fill switch is ON)
• When the output to the 1st clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
the clutch is not disengaged.
Problem that
appears on machine

1 1st clutch fill switch defective When dis-
Between CN7 (male) and chas- engaged
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-525

(7)
TROUBLESHOOTING [15SEMA]
[15SEMA] 1ST CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 1st clutch solenoid • Malfunction (MA)
E03 15SEMA TM sensed)
• When a signal is output to the 1st clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN6 (female)
sensor
4
fective
and ATC2 (female)
20-526 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SFL1]
[15SFL1] 2ND CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 2nd clutch solenoid • See separate list (L1)
Trouble
E03 15SFL1 TM (Command is OFF and fill switch is ON)
• When the output to the 2nd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

2nd clutch fill switch defec-
1 When dis-
tive Resistance Min. 1 Mz
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-527

(7)
TROUBLESHOOTING [15SFMA]
[15SFMA] 2ND CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 2nd clutch solenoid • Malfunction (MA)
E03 15SFMA TM sensed)
• When a signal is output to the 2nd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-528 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SGL1]
[15SGL1] 3RD CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 3rd clutch solenoid • See separate list (L1)
Trouble
E03 15SGL1 TM (Command is OFF and fill switch is ON)
• When the output to the 3rd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

3rd clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-529

(7)
TROUBLESHOOTING [15SGMA]
[15SGMA] 3RD CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 3rd clutch solenoid • Malfunction (MA)
E03 15SGMA TM sensed)
• When a signal is output to the 3rd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN12 (female)
sensor
4
fective
and ATC2 (female)
20-530 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SHL1]
[15SHL1] 4TH CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 4th clutch solenoid • See separate list (L1)
Trouble
E03 15SHL1 TM (Command is OFF and fill switch is ON)
• When the output to the 4th clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

4th clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-531

(7)
TROUBLESHOOTING [15SHMA]
[15SHMA] 4TH CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 4th clutch solenoid • Malfunction (MA)
E03 15SHMA TM sensed)
• When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-532 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SJL1]
[15SJL1] LOCKUP CLUTCH SOLENOID • 15SJ (L1)
Action code Error code Controller code Lockup clutch solenoid • 15SJ (L1)
Trouble
E03 15SJL1 TM (Command is OFF and fill switch is ON)
• When the output to the lockup clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
• If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Lockup clutch fill switch de-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-533

(7)
TROUBLESHOOTING [15SJMA]
[15SJMA] LOCKUP CLUTCH SOLENOID • 15SJ (MA)
Action code Error code Controller code Lockup clutch solenoid • 15SJ (MA)
Trouble
E03 15SJMA TM (Command is OFF, fill switch is ON, and slip is sensed)
• When a signal is output to the lockup clutch ECMV, the signal from the fill switch is kept OFF and the
Contents of trouble value calculated from the signals of the engine speed sensor, transmission intermediate shaft speed
sensor, and transmission output shaft speed sensor is abnormal.
Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

Lockup clutch ECMV 3) Connect T-adapter.
1
defective Between CN20 (male) and Resistance 5 – 15 z
ground
2) Disconnect connector ATC5A and CN20.
Possible causes
ness
contact)
Resistance Max. 1 z
CN20 (female)
sensor
4
fective
and ATC2 (female)
20-534 HD465-7, HD605-7

(7)
TROUBLESHOOTING [2F00KM]
[2F00KM] PARKING BRAKE • MISTAKE IN OPERATION OR SETTING (KM)
Action code Error code Controller code Parking brake • Mistake in operation or setting (KM)
Trouble
Not set 2F00KM TM (Parking brake drags)
• When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency brake
Contents of trouble
is operated.
Problem that
• If the machine is used without repairing, it may be broken.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 31400)..

• Set the parking brake switch in the FREE position and then start the
Mistake in operation of park- machine.
1
ing brake switch • Stop the machine perfectly, and then set the emergency brake switch
in the FREE position and start the machine.
Relay
Yes
When the parking brake relay (R03) is re- (R03)
placed, is failure repaired? Relay
No
(R03)
Parking brake relay (R03) 3) Check the relay.
2
defective Between R03 (male) and Resistance 200 – 400 Ω
in normal state
Apply 24 V between
and Do not apply 24 V be-
tween and .
2) Disconnect connector PSW.
Parking brake oil pressure Set parking brake
3
switch defective switch in FREE posi- Resistance Min. 1 MΩ
Between PSW (male) position.
and Set parking brake
switch in PARK posi- Resistance Max. 1 Ω
tion.
Mistake in operation of
emergency brake
4 • Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
HD465-7, HD605-7 20-535

➀
TROUBLESHOOTING [2F00KM]

Wiring harness between R03 (female) ,
and chassis ground
ness 1) Turn the starting switch OFF.
5
(Disconnection or defective 2) Disconnect connectors R03, BT3, and PSW.
contact) 3) Connect T-adapter.
Wiring harness between fuse BT3 and PSW
(female)
PSW (female)
Possible causes
and standard value 2) Disconnect connectors BRC5A and R03.
in normal state Grounding fault of wiring 3) Connect T-adapter.
6
harness
Between BRC5A (female), R03 (female)
and chassis ground
2) Disconnect connector BRC5A.
4) Connect connector BRC5A
7 Retarder controller defective Set parking brake
switch in FREE posi- Voltage Max. 1 V
Between BRC5A tion.
and chassis ground Set parking brake
switch in PARK posi- Voltage 20 – 30 V
tion.
20-536 HD465-7, HD605-7

➀
TROUBLESHOOTING [989A00]
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL • OPERATION (00)

Trouble Engine overrun prevention command signal • Operation (00)
E02 989A00 TM
• When the gear speed is not in neutral, the transmission input shaft speed signal rises higher than 2,600
Contents of trouble
rpm.
Action of controller • The controller sends a command signal to the retarder controller to apply the brake.
Problem that
• The brake operates and the travel speed lowers.
appears on machine

★ If the machine is traveling under the condition where the transmission
Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2,600 rpm, the engine is
and standard value overrunning.
in normal state • If the machine is not traveling under the condition where the transmis-
2 sion input shaft speed signal rises higher than 2,600 rpm, the trans-
fective
mission controller is defective.
HD465-7, HD605-7 20-537

➀
TROUBLESHOOTING [989AKZ]
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL • DISCONNECTION

OR SHORT CIRCUIT (KZ)
Action code Error code Controller code Engine overrun prevention command signal • Disconnection or
Trouble
E01 989AKZ TM short circuit (KZ)
• There is disconnection, grounding fault, or short circuit with power source in the engine overrun pre-
Contents of trouble
vention command signal circuit.
Action of controller • The controller continues the control with the S-NET signal.
Problem that
• This failure does not have a serious effect on the machine.
appears on machine
Related information • None in particular.

2) Disconnect connectors ATC1 and BRC5B.
ness
1 Wiring harness between ATC1 (female) and
(Disconnection or defective Resistance Max. 1 Ω
BRC5B (female)
contact)
Wiring harness between fuse BT3 Voltage between ATC1
20 – 30 V
terminal and ATC1 (female) and chassis ground
2) Disconnect connectors ATC1 and BRC5B.
Grounding fault of wiring
2 Resistance value be-
harness
Wiring harness between ATC1 (fe- tween ATC1 (female)
Min. 1 MΩ
male) and BRC5B (female) , BRC5B (female)
and chassis ground
and standard value 2) Disconnect connectors ATC1 and BRC5B.
in normal state 3) Connect T-adapter.
Short circuit with power
3 Voltage between ATC1
source in wiring harness Wiring harness between ATC1
(female) , BRC5B
(female) and BRC5B (female) Max. 1 V
ground
2) Disconnect connector BRC1.
4 Retarder controller defective 4) Connect the connector.
Between BRC1 and chassis ground Voltage Max. 1 V
2) Disconnect connector TC5A.
5 4) Connect the connector.
fective
Between ATC1 and chassis ground Voltage Max. 1 V
20-538 HD465-7, HD605-7

➀
TROUBLESHOOTING [AA10NX]
[AA10NX] AIR CLEANER ELEMENT • CLOGGING (NX)

Trouble Air cleaner element • Clogging (NX)
E01 AA10NX TM
Contents of trouble • The air cleaner clogging signal circuit is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, the suction performance of the engine may be lowered.
appears on machine

The dust indicator is not red. Air cleaner is normal.
1 Clogging of air cleaner
The dust indicator is red. Air cleaner is clogged.
Relay (R32)
No
When the dust indicator relay (R32) is re- is normal.
placed, is failure repaired? Relay (R32)
Yes
is defective.
Dust indicator relay (R32) 3) Check the relay.
2
defective
Between R32 (male) and Resistance 200 – 400 z
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween and .
and standard value 2) Disconnect connectors FR01.
in normal state Air cleaner clogging sensor 3) Connect T-adapter.
3
defective
Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z
and Air cleaner is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and R32.
ness Wiring harness between ATC3A (female)
4 Resistance Max. 1 z
and R32 (female)
contact)
Wiring harness between ATC3A (female)
Resistance Max. 1 z
and R32 (female)
2) Disconnect connector R32 and FR01.
Grounding fault of wiring 3) Connect T-adapter.
5
harness Resistance value be-
Wiring harness between R32
tween R32 (female) Min. 1 Mz
(female) and FR01 (female) , FR01 (female)
2) Disconnect connectors ATC3A.
Transmission controller de- 4) Connect connector.
6
Between ATC3A Air cleaner is normal. Voltage 20 – 30 V
and Air cleaner is clogged. Voltage Max. 1 V
HD465-7, HD605-7 20-539

(7)
TROUBLESHOOTING [AA10NX]
20-540 HD465-7, HD605-7

#
TROUBLESHOOTING [AB00MA]
[AB00MA] ALTERNATOR • MALFUNCTION (MA)
Action code Error code Controller code Alternator • Malfunction (MA)

Trouble
E03 AB00MA TM (Failure in battery charging circuit)
Contents of trouble • A generation signal is not input from the alternator while the engine is running.
Problem that • If the machine is used without repairing, the source voltage may lower so much that the machine cannot
appears on machine travel.

2) Disconnect connector alternator terminal R.
1 Alternator defective
Between alternator R and E Voltage 20 – 30 V
★ If the battery is deteriorated or used in a cold district, the voltage may
not rise for a while after the engine is started.
2) Disconnect connector ATC3B.
Disconnection in wiring har- Wiring harness between Voltage between ATC3B (fe-
20 – 30 V
Possible causes ness ATC3B (female) and al- male) and chassis ground
and standard value 2 (Disconnection or defective ternator terminal R Resistance Max. 1 Ω
in normal state contact) ★ If the battery is deteriorated or used in a cold district, the voltage may
Wiring harness between battery relay terminal
M and alternator terminal R
3 5) Start the engine.
fective
Between ATC3B and chassis ground Voltage 20 – 30 V
★ If the battery is deteriorated or used in a cold district, the voltage may
HD465-7, HD605-7 20-541

➁
TROUBLESHOOTING [AB00MA]
20-542 HD465-7, HD605-7

➀
TROUBLESHOOTING [D1BOKZ]
HD465-7, HD605-7 20-545

➀
TROUBLESHOOTING [D5ZMKZ]
[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE

OUTPUT MODE COMMAND LINE • DISCONNECTION OR SHORT CIRCUIT
(KZ)
Action code Error code Controller code Disconnection, grounding fault, or short circuit in engine output
Trouble
E01 D5ZMKZ TM mode command line • Disconnection or short circuit (KZ)
Contents of trouble • Disconnection, grounding fault, or short circuit occurs in engine output mode command line.
Action of controller • The controller controls in the power mode (The machine is fixed to the power mode).
Problem that
appears on machine

Disconnection in wiring har- 2) Disconnect connectors ATC1 and ECMB.
1
ECMB (female)
2) Disconnect connectors ATC1 and ECMB.
ATC1 (female) , ECMB
ATC1 (female) and Min. 1 MΩ
ECMB (female)
ground
2) Disconnect connectors ATC5A and BRC5B.
Possible causes Short circuit with power 3) Connect T-adapter.
3
and standard value source
Between ATC1 (female) , ECMB (female)
in normal state Voltage Max. 1 V
and chassis ground
4 Engine controller defective 4) Connect the connector.
Between ECMB In power mode Voltage 9.4 – 12 V
and chassis ground In economy mode Voltage 0 – 2.4 V
Transmission controller de- 4) Disconnect the connector.
5
fective 5) Start the engine.
Between ATC1 and In power mode Voltage 9.4 – 12 V
chassis ground In economy mode Voltage 0 – 2.4 V
20-546 HD465-7, HD605-7

➀
TROUBLESHOOTING [DAQ0KK]
[DAQ0KK] TRANSMISSION CONTROLLER • LOWERING OF SOURCE/INPUT VOLTAGE

(KK)

Trouble Transmission controller • Lowering of source/input voltage (KK)
E03 DAQ0KK TM
• While the engine is running, the voltages of both main power source voltage circuit and direct power
Contents of trouble
source voltage circuit lower below 18 V.
Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage
appears on machine rises to the normal level.
• If error code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) , , and for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Battery defective
Specific
Specific gravity of battery fluid Min. 1.26
gravity
Wiring harness between ATC1 (female) ,
and chassis ground
Disconnection in wiring har- 4) Connect the connector.
ness
2
(Disconnection or defective Wiring harness between battery, Voltage between ATC1
contact) battery relay terminal B, and ATC1 20 – 30 V
Possible causes and ,
and standard value
in normal state
Wiring harness between battery re- Voltage between ATC1
20 – 30 V
lay terminal M and ATC1 , , and ,
2) Disconnect connector ATC1
Between ATC1 and , Voltage 20 – 30 V
3 1) Turn the starting switch OFF.
fective
2) Disconnect connector ATC1
Between ATC1 , and , Voltage 20 – 30 V
HD465-7, HD605-7 20-547

➀
20-548 HD465-7, HD605-7

➀
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER • LOWERING OF

SOURCE/INPUT VOLTAGE (KK)
Action code Error code Controller code Main power line of transmission controller • Lowering of source/
Trouble
E03 DAQ1KK TM input voltage (KK)
Contents of trouble • The main power source voltage is lower than the direct power source voltage by 5 V or more.
Action of controller • The controller prohibits updating of information about input.
Problem that
• The condition before the failure is kept.
appears on machine
• If the fuse is broken, check the line between the fuse and ATC1 (female) and for grounding fault.
Related information
( 1: 4/15, by MIYA)

and chassis ground
ness
1 Voltage between bat-
(Disconnection or defective Wiring harness between battery
contact) tery relay terminal B 20 – 30 V
Possible causes and battery relay terminal B
and chassis ground
and standard value
in normal state 1) Turn the starting switch OFF.
Wiring harness between battery re- Voltage between ATC1
20 – 30 V
lay terminal M and ATC1 , , and ,
Transmission controller de- 3) Insert T-adapter.
fective
Between ATC1 , and , Voltage 20 – 30 V
HD465-7, HD605-7 20-549

➀
20-550 HD465-7, HD605-7

➀
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE • LOWERING OF

Action code Error code Controller code Transmission controller load power line • Lowering of source/in-
Trouble
E03 DAQ2KK TM put voltage (KK)
Contents of trouble • While the transmission controller source voltage is normal, the solenoid source voltage is below 18 V.
• The controller turns the transmission cutout relay OFF.
• The controller sets the gear in Neutral.
Problem that
• The gear is set in Neutral suddenly during travel and the machine cannot start again.
appears on machine
Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) and for grounding fault.

3) Turn the starting switch ON
Relay (R15)
No
When transmission cutout relay (R15) is re- is normal.
placed, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay (R15) defective
3) Check the relay.
Apply 24 V between
Possible causes
and standard value and Do not apply voltage
in normal state between and .
2) Disconnect connectors R15.
Disconnection in wiring har- Wiring harness between fuse BT-3 Voltage between R15
ness (female) and chas- 20 – 30 V
2 – 14 and R15 (female)
(Disconnection or defective sis ground
contact) 1) Turn the starting switch OFF.
2) Disconnect connectors ATC2 and R15.
Wiring harness between ATC2 , and R15
(female)
fective
Between ATC2 , and chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-551

➀
20-552 HD465-7, HD605-7

➀
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY • LOWERING

OF SOURCE/INPUT VOLTAGE (KK)
Action code Error code Controller code Direct line of transmission controller battery • Lowering of source/
Trouble
E03 DAQ3KK TM input voltage (KK)
Contents of trouble • The direct power source voltage is below 5 V. ( 1: 4/15, by MIYA)
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) for grounding fault.

Disconnection in wiring har- and chassis ground
1
(Disconnection or defective 2) Disconnect connector ATC1.
Possible causes contact) 3) Insert T-adapter.
in normal state Wiring harness between battery,
Voltage between ATC1
battery relay terminal B, and ATC1 20 – 30 V
and ,

fective
Between ATC1 and , Voltage 20 – 30 V
HD465-7, HD605-7 20-553

➀
TROUBLESHOOTING [DAQ9KM]
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS • MISTAKE IN

OPERATION OR SETTING (KM)
Action code Error code Controller code Transmission controller wiring harness • Mistake in operation or
Trouble
E03 DAQ9KM TM setting (KM)
• The connector check signal, that is input when the starting switch is turned to the ON position, does not
Contents of trouble
agree with setting in the controller.
Action of controller • The controller keeps the gear speed in neutral.
• This failure is not recorded in the failure history.
Problem that
• When the starting operation is performed, the machine does not start.
appears on machine

The connector of the connector check signal is connected normally.
Wrong connection of con-
1 ★ Connector check signal connector: ATC3A (OPEN), ATC5A
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector ATC5A.
2
and chassis ground
Possible causes
and standard value
Grounding fault in wiring 3) Connect T-adapter.
in normal state 3
Wiring harness between ATC3A
tween ATC3A (female) Min. 1 MΩ
(female) and chassis ground
and chassis ground
fective Resistance Max. 1 Ω
and chassis ground
Between ATC3A (female) and chassis
ground
20-554 HD465-7, HD605-7

➀
TROUBLESHOOTING [DAQ9KQ]
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS • DISAGREEMENT OF

MODEL SELECTION SIGNALS (KQ)
Action code Error code Controller code Transmission controller wiring harness • Disagreement of model
Trouble
E03 DAQ9KQ TM selection signals (KQ)
Contents of trouble • Transmission controller wiring harness • Disagreement of model selection signals (KQ)
Action of controller • The controller sets the gear speed in neutral.
Problem that
appears on machine

ness
and chassis ground
contact)
and chassis ground
Possible causes harness
and standard value Min. 1 MΩ
(female) and MS21 (female) , MS21 (female)
in normal state
and chassis ground
Wrong setting of rotary • For setting of the rotary switch, see ADJUSTING TRANSMISSION
3
switch CONTROLLER.
Wrong setting of rotary Resistance Max. 1 Ω
4 ground
switch
ground
ground
HD465-7, HD605-7 20-555

➀
TROUBLESHOOTING [DAQAKQ], [DAQSMA]
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH • DISAGREEMENT OF

Action code Error code Controller code Transmission controller wiring harness • Disagreement of model
Trouble
E03 DAQ9KQ TM selection signals (KQ)
Contents of trouble • Setting of the model by the rotary switch does not agree with setting in the controller.
Action of controller • The controller sets the gear speed in neutral.
Problem that
appears on machine

Wrong setting of rotary • For setting of the rotary switch, see ADJUSTING TRANSMISSION
Possible causes 1
switch CONTROLLER.
and standard value
in normal state • For setting of the rotary switch, see ADJUSTING TRANSMISSION
2 CONTROLLER.
fective
★ If setting is normal, the transmission controller is defective.
[DAQSMA] TRANSMISSION CONTROLLER • MALFUNCTION (MA)

Trouble Transmission controller • Malfunction (MA)
E03 DAQSMA TM
Contents of trouble • Communication with the machine monitor (S-NET) is defective and the optional items cannot be set.
Action of controller • The controller sets the gear speed in Neutral.
Problem that
appears on machine
• If error code "DAQSKR" of the machine monitor system is indicated, perform troubleshooting for it first.
Related information • Do not turn the starting switch to the left before starting the engine (Since the engine preheating system
is automatic, the starting switch does not need to be turned to the left).

Possible causes ★ If the failure is not repaired by replacing the transmission controller,
1 Machine monitor defective
and standard value the machine monitor is defective.
in normal state Transmission controller de- ★ If the failure is repaired by replacing the transmission controller, the
2
fective transmission controller is defective.
20-556 HD465-7, HD605-7

➀
TROUBLESHOOTING [DDTGKA]
[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code Lockup clutch fill switch: Disconnection (KA)
Trouble (Command is Holding pressure, fill switch is OFF, and slip is not
E03 DDTGKA TM sensed)
• When the output to the lockup clutch ECMV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.
• The controller keeps the current gear speed.
• The gear cannot be shifted.
Problem that
• If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
appears on machine
• The lockup pilot lamp does not light up.

Lockup clutch fill switch de-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21.
2 3) Connect T-adapter.
in normal state (Disconnection or defective
contact) Resistance Max. 1 z
and CN21 (female)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-557

(9)
TROUBLESHOOTING [DDTHKA]
[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code Hi clutch fill switch: Disconnection (KA)
E03 DDTHKA TM sensed)
• When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble
switch is not turned ON.
Problem that • The gear cannot be shifted.

1 Hi clutch fill switch defective When dis-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN19.
and CN19 (female)
3 When dis-
Resistance Max. 1 z
gaged
20-558 HD465-7, HD605-7

(9)
TROUBLESHOOTING [DDTJKA]
[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code Lo clutch fill switch: Disconnection (KA)
E03 DDTJKA TM sensed)
• When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 Lo clutch fill switch defective When dis-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN17.
and CN17 (female)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-559

(9)
TROUBLESHOOTING [DDTKKA]
[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code 1st clutch fill switch: Disconnection (KA)
E03 DDTKKA TM sensed)
• When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 1st clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged
and CN7 (female)
3 When dis-
Resistance Max. 1 z
gaged
20-560 HD465-7, HD605-7

(9)
TROUBLESHOOTING [DDTLKA]
[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code 2nd clutch fill switch: Disconnection (KA)
E03 DDTLKA TM sensed)
• When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.

2nd clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
and CN9 (female)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-561

(9)
TROUBLESHOOTING [DDTMKA]
[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code 3rd clutch fill switch: Disconnection (KA)
E03 DDTMKA TM sensed)
• When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

3rd clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
and CN13 (female)
3 When dis-
Resistance Max. 1 z
gaged
20-562 HD465-7, HD605-7

(9)
TROUBLESHOOTING [DDTNKA]
[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Error code Controller code R clutch fill switch: Disconnection (KA)
E03 DDTNKA TM sensed)
• When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 R clutch fill switch defective When dis-
Resistance Max. 1 z
gaged
and CN11 (female)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-563

(9)
TROUBLESHOOTING [DDTPKA]
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA)
Action code Error code Controller code 4th clutch fill switch : Disconnection (KA)
E03 DDTPKA TM sensed)
• When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

4th clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
and CN15 (female)
3 When dis-
Resistance Max. 1 z
gaged
20-564 HD465-7, HD605-7

(9)
TROUBLESHOOTING [DF10KA]
[DF10KA] SHIFT LEVER: DISCONNECTION (KA)

Trouble Shift lever: Disconnection (KA)
E03 DF10KA TM
Contents of trouble • The shift lever signal is not input at all.
Action of controller • The controller keeps the condition before occurrence of the failure..
• The gear may be shifted up above the gear speed set with the shift lever.
Problem that • The gear is kept in neutral and the machine cannot start.
appears on machine • The travel direction cannot be changed.
• All the shift lever position lamps go off.

• The shift lever is pressed by some force while it is not operated.
1 Wrong operation
• The shift lever is stopped between 2 positions.
2) Disconnect connector SF1.
Wiring harness between BT3 and SF1 (fe-
male)
2) Disconnect connectors ATC5B and SF1.
Wiring harness between ATC5B (female)
and SF1 (female)
Disconnection in wiring har- and SF1 (female)
ness Wiring harness between ATC5B (female)
2 (Disconnection or defective and SF1 (female) Resistance Max. 1 Ω
contact of connector)
and SF1 (female)
Possible causes and SF1 (female)
and standard value Wiring harness between ATC5B (female)
in normal state Resistance Max. 1 Ω
and SF1 (female)
and SF1 (female)
and SF1 (female)
and SF1 (female)
Resistance value be-
Wiring harness between ATC5B tween ATC5B (female)
Min. 1 MΩ
(female) – SF1 (female) , SF1 (female)
and chassis ground
Min. 1 MΩ
and chassis ground
Min. 1 MΩ
and chassis ground
HD465-7, HD605-7 20-565

➀

Min. 1 MΩ
and chassis ground
Min. 1 MΩ
and chassis ground
Min. 1 MΩ
Short circuit with power and chassis ground
3
source in wiring harness Resistance value be-
Min. 1 MΩ
and chassis ground
Min. 1 MΩ
and chassis ground
Min. 1 MΩ
and chassis ground
Possible causes 5) Turn the starting switch ON.
and standard value When shift range is "R" Voltage 20 – 30 V
in normal state Between SF1 and
chassis ground When shift range is not
Voltage Max. 1 V
"R"
When shift range is "N" Voltage 20 – 30 V
Between SF1 and
Voltage Max. 1 V
"N"
When shift range is "D" Voltage 20 – 30 V
Between SF1 and
When shift range is not
chassis ground Voltage Max. 1 Ω
"D"
When shift range is "6" Voltage 20 – 30 V
Between SF1 and
4 Shift lever defective Voltage Max. 1 V
"6"
Between SF1 and
Voltage Max. 1 V
"5"
Between SF1 and
Voltage Max. 1 V
"4"
Between SF1 and
Voltage Max. 1 V
"3"
Between SF1 and
Voltage Max. 1 V
"2"
Between SF1 and
Voltage Max. 1 V
"1"
20-566 HD465-7, HD605-7

➀

4) Connect connector ATC5B.
When shift range is "R" Voltage 20 – 30 V
Between ATC5B
and chassis ground When shift range is not
Voltage Max. 1 V
"R"
Between ATC5B
Voltage Max. 1 V
"N"
Between ATC5B
When shift range is not
and chassis ground Voltage Max. 1 Ω
"D"
Possible causes Between ATC5B
and standard value Transmission controller de- and chassis ground When shift range is not
5 Voltage Max. 1 V
in normal state fective "6"
Between ATC5B
Voltage Max. 1 V
"5"
Between ATC5B
Voltage Max. 1 V
"4"
Between ATC5B
Voltage Max. 1 V
"3"
Between ATC5B
Voltage Max. 1 V
"2"
Between ATC5B
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-567

➀
20-568 HD465-7, HD605-7

➀
TROUBLESHOOTING [DF10KB]
[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB)

Trouble Shift lever: Short circuit (KB)
E03 DF10KB TM
Contents of trouble • The shift lever signals are input from 2 or more systems.
• The controller controls with the signal having higher priority.
: N > D > 6 > 5 > 4 > 3 > 2 > 1.
:N>R
• If the signals of systems and are input simultaneously, the controller sets the gear in neutral.
• The gear may be shifted up above the gear speed set with the shift lever.
Problem that
• The gear is kept in neutral and the machine cannot start.
appears on machine
• The shift lever position lamp is different from the shift lever position.

Voltage between
Wiring harness between ATC5B ATC5B (female) ,
Max. 1 V
(female) – SF1 (female) SF1 (female) and
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
Possible causes Short circuit in wiring har- chassis ground
in normal state 1 Voltage between
(Short circuit with power
source) Wiring harness between ATC5B ATC5B (female) ,
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
HD465-7, HD605-7 20-569

➀

Between SF1 and
Voltage Max. 1 V
"R"
Between SF1 and
Voltage Max. 1 V
"N"
Between SF1 and When shift range is "D" Voltage 20 – 30 V
Voltage Max. 1 Ω
"D"
Between SF1 and
2 Shift lever defective Voltage Max. 1 V
"6"
Between SF1 and
Voltage Max. 1 V
"5"
Between SF1 and When shift range is "4" Voltage 20 – 30 V
Voltage Max. 1 V
"4"
Between SF1 and
Possible causes Voltage Max. 1 V
"3"
and standard value
in normal state Between SF1 and
Voltage Max. 1 V
"2"
Between SF1 and
Voltage Max. 1 V
"1"
When the right FNR switch is installed (Turn the right FNR switch ON)
Between ATC5B
Voltage Max. 1 V
"R"
Transmission controller de- Between ATC5B When shift range is not
3 and chassis ground Voltage Max. 1 V
fective "N"
Between ATC5B
Voltage Max. 1 V
"D"
Between ATC5B When shift range is "6" Voltage 20 – 30 V
Voltage Max. 1 Ω
"6"
Between ATC5B
Voltage Max. 1 V
"5"
20-570 HD465-7, HD605-7

➀

Between ATC5B
Voltage Max. 1 V
"4"
Between ATC5B When shift range is "3" Voltage 20 – 30 V
Possible causes and chassis ground When shift range is not
Transmission controller de- Voltage Max. 1 V
and standard value "3"
in normal state 3 fective
Between ATC5B
Voltage Max. 1 V
"2"
Between ATC5B
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-571

➀
TROUBLESHOOTING [DGF1KX]
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT

SIGNAL RANGE (KX)
Action code Error code Controller code Transmission valve oil temperature sensor: Out of input signal
Trouble
E03 DGF1KX TM range (KX)
• The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0.97 V (above
Contents of trouble
150°C) or very different from the torque converter oil temperature signal.
Action of controller • The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
Problem that
• Gear shift shocks become large.
appears on machine
Related information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Transmission oil tempera- 3) Connect T-adapter.
1
ture sensor defective
Between CN24 (male) Oil temperature: 25°C Resistance 37 – 50 kΩ
and Oil temperature: 100°C Resistance 3.5 – 4.0 kΩ
2) Disconnect connectors ATC3A, ATC3B, and CN24.
ness
2 Wiring harness between ATC3B (female)
and CN24 (female)
contact)
and CN24 (female)
2) Disconnect connectors ATC3B and CN24.
Possible causes 3 Resistance value be-
harness
and standard value Wiring harness between ATC3B tween ATC3B (female)
in normal state Min. 1 MΩ
and chassis ground
4
source in wiring harness Voltage between
Max. 1 V
(female) and CN24 (female) CN24 (female) and
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
5 5) Turn the starting switch ON.
fective
Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kΩ
male) and ATC3A
(female) Oil temperature: 100°C Resistance 3.5 – 4.0 kΩ
20-572 HD465-7, HD605-7

➀
TROUBLESHOOTING [GDF1KX]
HD465-7, HD605-7 20-573

➀
TROUBLESHOOTING [DGT1KX]
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF

INPUTSIGNAL RANGE (KX)
Action code Error code Controller code Torque converter oil temperature sensor: Out of input signal
Trouble
E01 DGT1KX TM range (KX)
• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above
Contents of trouble
150°C) or very different from the transmission valve oil temperature signal.
Problem that
• The torque converter oil temperature gauge does not indicate normally.
appears on machine

Torque converter oil temper- 3) Connect T-adapter.
1
ature sensor defective
Between CN23 (T/C-T) Oil temperature: 25°C Resistance 37 – 50 kΩ
(male) and Oil temperature: 100°C Resistance 3.5 – 4.0 kΩ
2) Disconnect connectors ATC3A, ATC3B, and CN23.
ness
2 Wiring harness between ATC3B (female)
and TC-SE (female)
contact)
and CN23 (female)
Possible causes Grounding fault in wiring
and standard value harness
in normal state Min. 1 MΩ
and chassis ground
4
Max. 1 V
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
fective
Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kΩ
male) and ATC3A
(female) Oil temperature: 100°C Resistance 3.5 – 4.0 kΩ
20-574 HD465-7, HD605-7

➀
TROUBLESHOOTING [DHT5KX]
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL

RANGE (KX)
Action code Error code Controller code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX TM (KX)
• The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above 4.5
Contents of trouble
V.
Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
• Large shocks are made when the lockup system is operated.
appears on machine

2) Disconnect connectors ATC1, ATC3A and CN22.
Disconnection in wiring har- Wiring harness between ATC3A (female)
1 and CN22 (female)
and CN22 (female)
CN22 (female)
Grounding fault in wiring Min. 1 MΩ
2 (female) and CN22 (female) , CN22 (female)
harness
and chassis ground
Wiring harness between ATC1 (fe- tween ATC1 (female)
Min. 1 MΩ
male) and CN22 (female) , CN22 (female)
Possible causes and chassis ground
in normal state 2) Disconnect connectors ATC3B and CN22.
3
Wiring harness between ATC3A ATC3A (female) ,
0.8 – 2.0 V
chassis ground
Torque converter oil pres- 4) Connect the connector.
4
sure sensor defective 5) Turn the starting switch ON.
Between CN22 and Voltage 20 – 30 V
Between CN22 and Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3A.
5
Between ATC1 and ATC3A Voltage 20 – 30 V
Between ATC3A and Voltage 0.8 – 2.0 V
HD465-7, HD605-7 20-575

➀
TROUBLESHOOTING [DHT5KX]
20-576 HD465-7, HD605-7

➀
TROUBLESHOOTING [DHT5L6]
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: SEE SEPARATE LIST

(L6)

Trouble Torque converter oil pressure sensor: See separate list (L6)
E01 DHT5L6 TM
• While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter
Contents of trouble
oil pressure sensor.
Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
• Large shocks are made when the lockup system is operated.
appears on machine

1
Max. 1.2 V
chassis ground
Possible causes 2) Disconnect connector CN22.
and standard value 3) Insert T-adapter.
Torque converter oil pres- 4) Connect the connector.
in normal state 2
Between CN22 and Voltage 20 – 30 V
Between CN22 and Voltage 0.8 – 2.0 V
3
Between ATC1 and ATC3A Voltage 20 – 30 V
HD465-7, HD605-7 20-577

➀
TROUBLESHOOTING [DJF1KA]
[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA)

Trouble Fuel level sensor: Disconnection (KA)
E01 DJF1KA TM
Contents of trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Problem that
• The fuel level gauge does not indicate normally.
appears on machine

2) Disconnect connector T01.
1 Fuel level sensor defective
Between T01 Fuel level: When FULL Resistance Max. 12 Ω
(female) and
Fuel level: When EMPTY Resistance 74 – 100 Ω

Disconnection in wiring har- 2) Disconnect connectors ATC3A, ATC3B, and T01.
2 (Disconnection or defective Wiring harness between ATC3B (female)
contact) and T01 (female)
and T01 (female)
Possible causes
and standard value
2) Disconnect connectors ATC3B and T01.
in normal state
Short circuit with power 4) Turn the starting switch ON..
3
Max. 1 V
(female) and T01 (female) T01 (female) and
chassis ground
Transmission controller de- 5) Turn the starting switch ON.
4
fective
Between ATC3B Fuel level: When FULL Resistance Max. 12 Ω
(female) and
ATC3A (female) Fuel level: When EMPTY Resistance 74 – 100 Ω
20-578 HD465-7, HD605-7

➀
TROUBLESHOOTING [DK11KX]
[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Throttle angle sensor: Out of input signal range (KX)
E03 DK11KX TM
• The voltage of the signal circuit of the acceleration sensor for transmission control is below 0.6 V or
Contents of trouble
above 4.7 V.
• The controller controls the machine, assuming that the engine is at full throttle. (This is not related to
the engine control, however.)
Problem that • Gear shift shocks become large.
appears on machine • The gear is shifted up soon when the machine travels down a slope with the brake OFF.

2) Disconnect connectors ATC3A, ATC3B, and AS2.
Disconnection in wiring har- Wiring harness between ATC3B (female)
1 and AS2 (female)
and AS2 (female)
and AS2 (female)
2) Disconnect connectors ATC3A, ATC3B, and AS2.
Grounding fault in wiring Min. 1 MΩ
2 (female) and AS2 (female) , AS2 (female)
harness
and chassis ground
Min. 1 MΩ
(female) and AS2 (female) , AS2 (female)
in normal state 2) Disconnect connectors ATC3B and AS2.
3
Max. 1 V
(female) and AS2 (female) AS2 (female) and
chassis ground
Acceleration sensor defec- 4) Connect the connector.
4
tive 5) Turn the starting switch ON.
Between AS2 and Voltage 4.6 – 5.4 V
Between AS2 and Voltage 1.0 – 4.0 V
5
Between ATC3B and ATC3A Voltage 1.0 – 4.0 V
HD465-7, HD605-7 20-579

➀
20-580 HD465-7, HD605-7

➀
TROUBLESHOOTING [DLE2KA]
[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA)

Trouble Engine speed sensor: Disconnection (KA)
E03 DLE2KA TM
Contents of trouble • The signal circuit of the engine speed sensor is disconnected and signals are not input.
• The gear cannot be shifted.
Problem that
• If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
appears on machine
• The tachometer does not operate (but indicates 0 rpm).

• Press the sensor lightly against the flywheel ring gear, and then re-
Wrong adjustment of engine turn it by 1/2 – 3/4 turns.
1
speed sensor ★ For details, see TESTING AND ADJUSTING, "Adjustment of en-
gine speed sensor".
2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
2
tive Between E03 (male) and Resistance 500 – 1,000 Ω
Between E03 (male) , and chassis
Possible causes Resistance Min. 1 MΩ
ground
and standard value
2) Disconnect connectors ATC3A and E03.
ness
and E03 (female)
contact)
and E03 (female)
Transmission controller de- 2) Disconnect connector ATC3A.
fective
Between ATC3A (female) and Resistance 500 – 1,000 Ω
HD465-7, HD605-7 20-581

➀
TROUBLESHOOTING [DLE2LC]
[DLE2LC] ENGINE SPEED SENSOR: SEE SEPARATE LIST (LC)

Trouble Engine speed sensor: See separate list (LC)
E01 DLE2LC TM
• When the engine speed sensor signal is below 350 rpm, the input transmission input shaft speed sen-
Contents of trouble
sor signal is above 500 rpm.

2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
1
tive Between E03 (male) and Resistance 500 – 1,000 Ω
Between E03 (male) , and chassis
ground
harness
Possible causes Wiring harness between ATC3A tween ATC3A (female)
Min. 1 MΩ
and standard value (female) and E03 (female) , E03 (female)
in normal state and chassis ground
3
Max. 1 V
(female) and E03 (female) E03 (female) and
chassis ground
fective
20-582 HD465-7, HD605-7

➀
TROUBLESHOOTING [DLF1KA]
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission input shaft speed sensor: Disconnection (KA)
E03 DLF1KA TM
• The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not in-
Contents of trouble
put.
Problem that • The lockup system is reset and the gear cannot be shifted.

• Press the sensor lightly against the revolution pickup gear, and then
Wrong adjustment of trans-
return it by 1/2 – 1 turn.
1 mission input shaft speed
★ For details, see TESTING AND ADJUSTING, "Adjustment of trans-
sensor
mission speed sensor".
Transmission input shaft 3) Connect T-adapter.
2
speed sensor defective Between CN3 (male) and Resistance 500 – 1,000 Ω
ground
and standard value
ness
and CN3 (female)
contact)
and CN3 (female)
fective
HD465-7, HD605-7 20-583

➀
TROUBLESHOOTING [DLF1LC]
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: SEE SEPARATE LIST

(LC)

Trouble Transmission input shaft speed sensor: See separate list (LC)
E01 DLF1LC TM
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sen-
Contents of trouble sor signal, and transmission output shaft speed sensor signal is different from the signal speed of the
transmission input shaft speed sensor.

Transmission input shaft 3) Connect T-adapter.
1
ground
harness
Min. 1 MΩ
and standard value (female) and CN3 (female) , CN3 (female)
3
Max. 1 V
chassis ground
fective
20-584 HD465-7, HD605-7

➀
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION

(KA)
Action code Error code Controller code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA TM (KA)
• The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are
Contents of trouble
not input.

1 mission intermediate shaft
speed sensor
Transmission intermediate 3) Connect T-adapter.
2 shaft speed sensor defective
Between CN4 (male) and Resistance 500 – 1,000 Ω
ground
and standard value
in normal state
3 Resistance Max. 1 Ω
(Disconnection or defective and CN4 (female)
contact)
and CN4 (female)
fective
HD465-7, HD605-7 20-585

➀
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:

SEE SEPARATE LIST (LC)
Action code Error code Controller code Transmission intermediate shaft speed sensor: See separate
Trouble
E03 DLF2LC TM list (LC)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission output shaft speed sensor signal is different from the signal speed of the trans-
mission intermediate shaft speed sensor.

Transmission intermediate 3) Connect T-adapter.
1
shaft speed sensor defective Between CN4 (male) and Resistance 500 – 1,000 Ω
ground
harness
Min. 1 MΩ
and standard value (female) and CN4 (female) , CN4 (female)
3
Max. 1 V
chassis ground
fective
20-586 HD465-7, HD605-7

➀
TROUBLESHOOTING [DLT3KA]
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission output shaft speed sensor: Disconnection (KA)
E03 DLT3KA TM
• The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
Contents of trouble
input.
appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral

return it by 1/2 - 1 turn.
1 mission output shaft speed
sensor
Transmission output shaft 3) Connect T-adapter.
2
Possible causes ground
in normal state 2) Disconnect connectors ATC3A and CN5.
and CN5 (female)
contact)
and CN5 (female)
fective
HD465-7, HD605-7 20-587

➀
TROUBLESHOOTING [DLT3LC]
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: SEE SEPARATE LIST

(LC)
Action code Error code Controller code Transmission output shaft speed sensor: See separate list
Trouble
E03 DLT3LC TM (LC)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission intermediate shaft speed sensor signal is different from the signal speed of the
transmission output shaft speed sensor.
appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral.

1
ground
2) Disconnect connectors ATC3A, BRC3A, and CN5.
2 ATC3A (female) ,
harness Wiring harness between ATC3A
BRC3A (female) ,
Possible causes (female) and BRC3A (female) Min. 1 MΩ
CN5 (female) and
and standard value (13) and CN5 (female)
chassis ground
in normal state
2) Disconnect connectors ATC3A, BRC3A, and CN5.
3 Voltage between
(female) and BRC3A (female) BRC3A (female) , Max. 1 V
and CN5 (female) (female) CN5 (female) and
chassis ground
fective
20-588 HD465-7, HD605-7

➀
TROUBLESHOOTING [DLT3KA]
HD465-7, HD605-7 20-589

#
TROUBLESHOOTING [DXH1KA]
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of lockup clutch solenoid: Discon-
Trouble
E01 DXH1KA TM nection (KA)
Contents of trouble • When a signal is output to the lockup clutch ECMV, any current does not flow.
Action of controller • The controller turns the lockup operation OFF.
Problem that
• The lockup system does not operate.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)

1
ground
2) Disconnect connectors ATC2 and CN20.
Possible causes
and standard value
in normal state ness Wiring harness between ATC2 (female)
and CN20 (female)
contact)
Resistance Max. 1 z
and CN20 (female)
3
fective
and ATC2 (female)
20-590 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DXH1KB]
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of lockup clutch solenoid: Short cir-
Trouble
E01 DXH1KB TM cuit (KB)
• When a signal is output to the lockup clutch ECMV, an abnormally large current flows, or some current
Contents of trouble
is flowing while the signal is OFF.
• The lockup system is reset and the gear cannot be shifted.
Problem that
• If the shift lever is set in the "N" position, the machine cannot start until it is stopped. (The machine
appears on machine
cannot start again, depending on the failure condition.)

1
ground
Possible causes Resistance value be-
and standard value Wiring harness between ATC2 (fe- tween ATC2 (female)
in normal state Short circuit in wiring har- Min. 1 Mz
2 male) and CN20 (female) , CN20 (female)
ness
and chassis ground
Between wiring harness between ATC2 (fe-
male) and CN20 (female) and wiring har-
ness between ATC2 (female) and CN20
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-591

(7)
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of Hi clutch solenoid: Disconnec-
Trouble
E03 DXH2KA TM tion (KA)
Contents of trouble • When a signal is output to the Hi clutch ECMV, any current does not flow.
Problem that • The gear is set in neutral during travel.
appears on machine • The machine cannot start again until it is stopped.

ground
Possible causes 2) Disconnect connectors ATC2 and CN18.
and standard value Disconnection in wiring har- 3) Connect T-adapter.
in normal state ness Wiring harness between ATC2 (female)
and CN18 (female)
contact)
Resistance Max. 1 z
and CN18 (female)
3
fective
and ATC2 (female)
20-592 HD465-7, HD605-7

(7)
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of Hi clutch solenoid: Short circuit
Trouble
E03 DXH2KB TM (KB)
• When a signal is output to the Hi clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
flowing while the signal is OFF.
• The gear is set in Neutral during travel.
Problem that
• The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-593

(7)
20-594 HD465-7, HD605-7

(7)
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of Lo clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the Lo clutch ECMV, any current does not flow.
Problem that • The gear is set in Neutral during travel.

ground
in normal state ness
CN16 (female)
contact)
Resistance Max. 1 z
male) and CN16 (female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-595

(7)
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of Lo clutch solenoid: Short circuit
Trouble
E03 DXH3KB TM (KB)
• When a signal is output to the Lo clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
• The machine cannot start until it is stopped.
appears on machine
(The machine cannot start again, depending on the failure condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
20-596 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-597

(7)
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 1st clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 1st clutch ECMV, any current does not flow.

ground
CN6 (female)
contact)
Resistance Max. 1 z
CN6 (female)
3
fective
ATC2 (female)
20-598 HD465-7, HD605-7

(7)
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 1st clutch solenoid: Short circuit
Trouble
E03 DXH4KB TM (KB)
• When a signal is output to the 1st clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-599

(7)
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 2nd clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 2nd clutch ECMV, any current does not flow.

ground
CN8 (female)
contact)
Resistance Max. 1 z
CN8 (female)
3
fective
ATC2 (female)
20-600 HD465-7, HD605-7

(7)
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 2nd clutch solenoid: Short circuit
Trouble
E03 DXH5KB TM (KB)
• When a signal is output to the 2nd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-601

(7)
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 3rd clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 3rd clutch ECMV, any current does not flow.

ground
CN12 (female)
contact)
Resistance Max. 1 z
CN12 (female)
3
fective
ATC2 (female)
20-602 HD465-7, HD605-7

(7)
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 3rd clutch solenoid: Short circuit
Trouble
E03 DXH6KB TM (KB)
• When a signal is output to the 3rd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
• The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-603

(7)
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of R clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the R clutch ECMV, any current does not flow.

ground
CN10 (female)
contact)
Resistance Max. 1 z
CN10 (female)
3
fective
ATC2 (female)
20-604 HD465-7, HD605-7

(7)
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of R clutch solenoid: Short circuit
Trouble
E03 DXH7KB TM (KB)
• When a signal is output to the R clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-605

(7)
TROUBLESHOOTING [DXHHKA]
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 4th clutch solenoid: Disconnec-
Trouble
E03 DXHHKA TM tion (KA)
Contents of trouble • When a signal is output to the 4th clutch ECMV, any current does not flow.

ground
CN14 (female)
contact)
Resistance Max. 1 z
CN14 (female)
3
fective
ATC2 (female)
20-606 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DXHHKB]
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 4th clutch solenoid: Short circuit
Trouble
E03 DXHHKB TM (KB)
• When a signal is output to the 4th clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female) ,
HD465-7, HD605-7 20-607

(7)
TROUBLESHOOTING TM-1
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY

(IT ALWAYS INDICATES "FULL")
Action code Error code Controller code Fuel level gauge does not operate normally
Trouble
Not set Not set Not set (It always indicates "FULL")
• The fuel level gauge does not operate normally because of grounding fault (short circuit with GND) in
Contents of trouble
the signal circuit of the fuel level sensor.
Problem that
• The fuel level gauge always indicates "FULL".
appears on machine
Related information • If error code "DJF1KA" is indicated, perform troubleshooting for it first.

1 Fuel level sensor defective
Between T01 Fuel level: When FULL Resistance Max. 12 z
(female) and
Possible causes Fuel level: When EMPTY Resistance 74 – 100 z
and standard value
2) Disconnect connectors ATC3B and T01.
harness
Min. 1 Mz
(female) and T01 (female) , T01 (female)
and chassis ground
20-608 HD465-7, HD605-7

#
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER

a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Action code Error code Controller code Abnormality in backup lamp and backup buzzer
Trouble a) When the shift lever is set in the "R" position, the backup lamp
Not set Not set Not set and backup buzzer are not turned ON
Contents of trouble • When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Problem that
• When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
appears on machine
• Before starting troubleshooting, check that fuse (BT-1) is normal.
Related information
• Error code is not displayed.

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
tween and .
Diode (D05)
No
When diode (D05) is replaced, is failure re- is normal.
Possible causes 2 Diode (D05) defective
and standard value paired? Diode (D05)
Yes
in normal state is defective.
2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse terminal.
Wiring harness between fuse BT1 terminal
and R05 (female)
Disconnection in wiring har- Wiring harness between R05 (female) and
ness D05 (female)
3
contact) Wiring harness between D05 (female) and
ATC5B (female) , and branch point of CNS Resistance Max. 1 Ω
(female)
Wiring harness between R05 (female) and Resistance Max. 1 Ω
chassis ground
CJT (female)
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, if fail- is normal
4
tive ure repaired? Joint con-
Yes nector (CJT)
is defective
HD465-7, HD605-7 20-609

➀
b) Backup lamp is not turned ON (Backup buzzer is normal)
Trouble
Not set Not set Not set b) Abnormality in backup lamp and backup buzzer
• When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
Contents of trouble
normal).
Problem that • When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
appears on machine normal).
Related information • Error code is not displayed.

Backup lamp bulb is not broken. Backup lamp is normal
1 Backup lamp defective
Backup lamp bulb is broken. Backup lamp is defective
Disconnection in wiring har- 2) Disconnect connectors B04 and CJT.
Possible causes 2
and standard value Wiring harness between CJT (female) and
in normal state B04 terminal
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
c) Backup buzzer is not turned ON (Backup lamp is normal)
Trouble
Not set Not set TM c) Backup buzzer is not turned ON (Backup lamp is normal)
• When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
Contents of trouble
normal).
Problem that • When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
appears on machine normal).
Cause Standard value in normal state/Remarks ON troubleshooting

2) Disconnect connectors B05, B06, and CJT.
Disconnection in wiring har- Wiring harness between CJT (female) and
1 chassis ground
Wiring harness between B06 terminal and CJT
(female) terminal
Possible causes
Wiring harness between B05 terminal and CJT
and standard value Resistance Max. 1 Ω
in normal state (female) terminal
When results of Item a) and Cause 1 above are Backup buzzer is
2 Backup buzzer defective
normal defective
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
20-610 HD465-7, HD605-7

➀
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON
Trouble d) While shift lever is not operated, backup lamp and backup
Not set Not set Not set buzzer are turned ON
Contents of trouble • While shift lever is not operated, backup lamp and backup buzzer are turned ON.
Problem that
• While shift lever is not operated, backup lamp and backup buzzer are turned ON.
appears on machine

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
Possible causes tween and .
in normal state 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse terminal.
Voltage between R05
Wiring harness between R05 (fe- (female) , D05 (fe-
Max. 1 V
male) and D05 (female) male) and chassis
ground
Wiring harness between D05 (fe-
Voltage between D05
male) and ATC5B (female) , Max. 1 V
Short circuit with power and branch point of CNS (female)
2 ground
Voltage between R05
Wiring harness between R05 (fe- (female) , CJT (fe- Max. 1 V
male) ( and CJT (female) male) and chassis
ground
Wiring harness between CJT (fe- Voltage between CJT Max. 1 V

(female) , B05 termi-
male) and B05 terminal
nal and chassis ground
Wiring harness between CJT (fe- Voltage between CJT

(female) , B04 termi- Max. 1 V
male) and B04 terminal
nal and chassis ground
HD465-7, HD605-7 20-611

➀
20-612 HD465-7, HD605-7

➀
TROUBLESHOOTING FOR RETARDER
CONTROLLER SYSTEM
(BK MODE)
Electrical system diagram related to retarder control .................................................................................. 20-704

Information in troubleshooting table ....................................................................................................... 20-706
Trouble code table ................................................................................................................................. 20-707
[2G42ZG] Accumulator (front): lowering of oil pressure (ZG).............................................................. 20-708
[2G43ZG] Accumulator (rear): lowering of oil pressure (ZG) .............................................................. 20-708
[D1C0KZ] Brake cutout relay: disconnection or short circuit (KZ) ....................................................... 20-709
[D5ZNKZ] Failure of front brake cutout output system (disconnection, grounding fault, short circuit)
(OPT): disconnection or short circuit (KZ) .......................................................................... 20-711
[DB10KK] Retarder controller: lowering of source/input voltage (KK) ................................................. 20-713
[DB11KK] Main power line of retarder controller: lowering of source/input voltage (KK) .................... 20-715
[DB12KK] Retarder controller load power line: lowering of source/input voltage (KK) ........................ 20-717
[DB13KK] Direct line of retarder controller battery: lowering of source/input voltage (KK).................. 20-719
[DB19KM] Retarder controller wiring harness: mistake in operation or setting (KM) ........................... 20-720
[DB1SKQ] Wrong information on model selection: disagreement of model selection signals (KQ)..... 20-721
[DDD7KX] Failure in travel speed set switch system (OPT): out of input signal range (KX)................ 20-722
[DDD8KA] ARSC system switch system: disconnection (KA).............................................................. 20-724
[DDD8KB] ARSC system switch system: short circuit (KB) ................................................................. 20-725
[dGR2L8] Failure In retarder oil temperature sensor system: see separate list (L8) ...................... 20-726
[DGR2L8] Brake oil temperature sensor (rear): see separate list (L8) ............................................ 20-727
[dHP4KX] Failure in suspension pressure sensor (FR) system (OPT): out of input signal range (KX) ... 20-728
[DHP4KX] Failure in suspension pressure sensor (FR) system (OPT): out of input signal range (KX) ... 20-730
[dHP5KX] Failure in suspension pressure sensor (FL) system (OPT): out of input signal range (KX).... 20-732
[DHP5KX] Failure in suspension pressure sensor (FL) system (OPT): out of input signal range (KX).... 20-734
[DHU2KX] Accumulator oil pressure sensor (front): out of input signal range (KX) ............................. 20-736
[DHU3KX] Accumulator oil pressure sensor (rear): out of input signal range (KX).............................. 20-738
[dK11KX] Failure in acceleration sensor system (OPT): out of input signal range (KX) ..................... 20-740
[DK11KX] Failure in acceleration sensor system (OPT): out of input signal range (KX) ..................... 20-741
[DK51L5] Retarder lever potentiometer: see separate list (L5) ...................................................... 20-742
[DK52KX] Dump lever potentiometer 1: out of input signal range (KX)............................................... 20-745
[DK53L8] Dump lever potentiometer 2: see separate list (L8) ....................................................... 20-747
[DK54KX] Body positioner sensor: out of input signal range (KX) ...................................................... 20-748
[DKD0L6] Failure in steering speed sensor (OPT): see separate list (L6) ...................................... 20-750
[dLt3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-752
[dLT3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-753
[DW35KZ] Failure in output system of auto suspension solenoid 1 (OPT) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754
[DW36KZ] Failure in output system of auto suspension solenoid 2 (OPT) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-755
[DW72KZ] Failure in kick-out solenoid output system (D_OUT3) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-756
[DW73KZ] Failure in hoist select valve output system (D_OUT5) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-758
[DK11K4] Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4) ......... 20-759-1
[DX11KA] Disconnection in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760
[DX11KB] Short circuit in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761
[DX11KY] Grounding fault in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): short circuit with power line (KY) ................................................ 20-762
HD465-7, HD605-7 20-701

➄
[DX11MA] Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)............. 20-762-1
[DX13KA] Disconnection in output circuit of hoist EPC valve (A_OUT3): disconnection (KA)............ 20-763
[DX13KB] Grounding fault in output circuit of hoist EPC valve (A_OUT3): short circuit (KB) ............. 20-764
[DX13KY] Short circuit in output circuit of hoist EPC valve (A_OUT3): short circuit with power line (KY).. 20-765
BK-1 Parking brake does not operate normally........................................................................... 20-767
a) When the parking brake switch is set in the OFF position, the parking brake
is not released............................................................................................................... 20-767
b) When the parking brake switch is set in the PARK position, the parking brake
does not work................................................................................................................ 20-769
BK-2 Retarder brake oil temperature gauge does not operate normally ..................................... 20-771
BK-3 Inclination alarm is turned ON when dump body is raised (when machine is not inclined
more than 15°).................................................................................................................... 20-772
BK-4 Touch up/down and cancellation cannot be performed ...................................................... 20-773
20-702 HD465-7, HD605-7

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER

CONTROL
20-704 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
HD465-7, HD605-7 20-705

➄

panel panel panel
Problem that
appears on machine

1
• Disconnection
• Short circuit
and standard value (Given numbers are refer-
3 <Precautions for troubleshooting>
in normal state ence numbers, which do not Method of indicating connector No. and handling of T-adapter
indicate priority)
Insert or connect T-adapter as explained below for troubleshooting,
side.
side.
5
side.
20-706 HD465-7, HD605-7

➀

TROUBLE CODE TABLE




MW Sliding
NS Overheat
HD465-7, HD605-7 20-707

➀
TROUBLESHOOTING [2G42ZG], [2G43ZG]
[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Front): Lowering of oil pressure (ZG)
E03 2G42ZG BK
• The signal of the front accumulator oil pressure sensor lowers below 13.2 MPa {135 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
• If the machine is used without repairing, the front brake may not work.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 35500)

• The front accumulator (brake) oil pressure is normal.
Possible causes Lowering of front accumula-
1 ★ If the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
• If the front accumulator (brake) oil pressure is normal, the retarder
2 Retarder controller defective
controller is defective.
[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Rear): Lowering of oil pressure (ZG)
E03 2G43ZG BK
• The signal of the rear accumulator oil pressure sensor lowers below 8.830 MPa {90 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
• If the machine is used without repairing, the rear brake may not work.
appears on machine

• The rear accumulator (brake) oil pressure is normal.
Possible causes Lowering of rear accumula-
1 ★ If the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
• If the rear accumulator (brake) oil pressure is normal, the retarder
controller is defective.
20-708 HD465-7, HD605-7

➀
TROUBLESHOOTING [D1C0KZ]
[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code Error code Controller code Brake cutout relay: Disconnection or short circuit (KZ)
Trouble
E03 D1C0KZ BK (Disconnection, grounding fault, or short circuit)
• When the output to the brake cutout relay circuit is turned ON, an abnormally large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
• The controller turns the output to the brake cutout relay OFF.
• When ARSC operates, the controller releases the brake gradually.
• The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC,
Problem that
ASR)
appears on machine
• Error codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

When the brake cutout relay (R14) No Relay (R14) is normal
is replaced, is failure repaired? Yes Relay (R14) is defective
3) Check the relay.
Brake cutout relay (R14) de-
1 Between R14 (male) and Resistance 200 – 400 Ω
fective
3) Check the relay.
Apply 24 V between
Between R14 (male) and
Resistance Min. 1 M Ω
tween and
2) Disconnect connectors BRC1 and R14.
Possible causes Wiring harness between fuse BR- Voltage between BRC1
20 – 30 V
and standard value 3- and BTC1 (female) and chassis ground
in normal state Wiring harness between fuse BT- Voltage between R14
Disconnection in wiring har- 20 – 30 V
ness 3- and R14 (female) and chassis ground
2
(Disconnection or defective 1) Turn the starting switch OFF.
contact) 2) Disconnect connectors BRC1, BRC2, and R14.
Wiring harness between BRC2 (female) ,
and R14 (female)
chassis ground
Wiring harness between BRC1 (female)
and R14 (female)
3
harness Wiring harness between Resistance between BRC1
BRC1 (female) and R14 (female) , R14 (female) Min. 1 M Ω
4
Wiring harness between Voltage between BRC1 (fe-
BRC1 (female) and R14 male) , R14 (female) Max. 1 V
HD465-7, HD605-7 20-709

➀
TROUBLESHOOTING [D1C0KZ]
20-710 HD465-7, HD605-7

➀
TROUBLESHOOTING [D5ZNKZ]
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (OPT):
DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Error code Controller code Failure of front brake cutout output system (Disconnection, grounding
Trouble fault, short circuit) (OPT): Disconnection or short circuit (KZ)
E03 D5ZNKZ BK (Disconnection, grounding fault, or short circuit)
• When the output to the front brake cutout switch circuit is turned ON, an abnormally large current flows
Contents of trouble
or any current does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to the brake cutout switch circuit OFF.
Problem that • When the front brake cutout switch is turned ON, the front brake cutout system does not work. Or, the
appears on machine front brake cutout system works while the switch is OFF.
Related information • This failure can be checked in the monitoring function (Code: 37600, 39100)

2) Disconnect connector FBC.
3) Check the switch.
Turn the front brake cutout
Front brake cutout switch Between FBC Resistance Min. 1 M Ω
1 switch OFF (Press it up).
defective (male) and
Turn the front brake cutout
switch ON (Press it down).
★ When the front brake cutout switch is turned ON (pressed down), the
front brake is cut out (the front brake does not operate).
2) Disconnect connectors DPC2B and FBC.
Disconnection in wiring har- Wiring harness between DPC2B (female)
2 and FBC (female)
Wiring harness between fuse BTC-4 and
FBC (female)
Wiring harness between FBC (female) and
chassis ground
Possible causes
and standard value
in normal state Resistance between
Grounding fault in wiring Wiring harness between DPC2B DPC2B (female) ,
3 Min. 1 M Ω
harness (female) and FBC (female) FBC (female) and
chassis ground
Wiring harness between fuse Resistance between
BTC-4 and FBC (female) FBC (female) and Min. 1 M Ω
★ In this case, the fuse is broken. chassis ground
4
Wiring harness between Voltage between DPC2B
DPC2B (female) and (female) , FBC (female) Max. 1 V
FBC (female) and chassis ground
2) Disconnect connector DPC2B
5 Machine monitor defective 5) Turn the starting switch ON.
Turn the cutout switch OFF
Between Voltage 20 – 30 V
(Press it up).
DPC2B and
chassis ground Turn the cutout switch ON
Voltage Max. 1 V
(Press it down).
HD465-7, HD605-7 20-711

➀
TROUBLESHOOTING [D5ZNKZ]
20-712 HD465-7, HD605-7

➀
TROUBLESHOOTING [DB10KK]
[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)

Trouble Retarder controller: Lowering of source/input voltage (KK)
E03 DB10KK BK
• The voltages of both main power source voltage circuit and direct power source voltage circuit are be-
Contents of trouble
low 17 V.
Action of controller • None in particular. (The controller works as long as possible.)
Problem that
appears on machine
• If error code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) , , and for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
1 Battery defective Battery voltage Voltage Min. 24 V
Specific gravity of battery fluid Specific gravity Min. 1.26
and chassis ground
ness Voltage between
2
(Disconnection or defective Wiring harness between battery, battery BRC1 and , 20 – 30 V
contact) relay terminal B, and BRC1
Possible causes
and standard value
in normal state
Voltage between
Wiring harness between battery relay
BRC1 , 20 – 30 V
terminal M and BRC1 ,
and ,
2) Disconnect connector BRC1
Between BRC1 and , Voltage 20 – 30 V
3 Retarder controller defective 1) Turn the starting switch OFF.
Between BRC1 , and , Voltage 20 – 30 V
HD465-7, HD605-7 20-713

➀
20-714 HD465-7, HD605-7

➀
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF

Action code Error code Controller code Main power line of retarder controller • Lowering of source/input volt-
Trouble
E03 DB11KK BK age (KK)
Contents of trouble • The difference between the main power source voltage and direct power source voltage is 5 V or more.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) and for grounding fault.

and chassis ground
ness Voltage between bat-
1
(Disconnection or defective Wiring harness between battery tery relay terminal B 20 – 30 V
contact) and battery relay terminal B
in normal state 2) Disconnect connector BRC1.
Voltage between
Wiring harness between battery
BRC1 , and , 20 – 30 V
relay terminal M and BRC1 ,

Between BRC1 , and , Voltage 20 – 30 V
HD465-7, HD605-7 20-715

➀
20-716 HD465-7, HD605-7

➀
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/

INPUT VOLTAGE (KK)
Action code Error code Controller code Retarder controller load power line • Lowering of source/input
Trouble
E03 DB12KK BK voltage (KK)
Contents of trouble • While the controller source voltage is normal, the solenoid source voltage is below 17 V.
• The controller turns the all output circuits OFF..
• The controller turns the 24 V sensor power source OFF.
Problem that
ASR)
appears on machine
• Error codes (DHU2KX, DHU3KX) are displayed, too.
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) and for grounding fault.

When brake cutout relay (R14) is No Relay (R14) is normal.
replaced, is failure repaired? Yes Relay (R14) is defective.
3) Check the relay.
1 Brake cutout relay defective Between R14 (male) and Resistance 200 – 400 Ω
3) Check the relay.
Apply 24 V between
Between R14 (male) and
Possible causes and Do not apply voltage
and standard value between and
2) Disconnect connectors R14.
Disconnection in wiring har- Wiring harness between fuse BT- Voltage between R14
ness (female) and chas- 20 – 30 V
2 3- and R14 (female)
(Disconnection or defective sis ground
contact) 1) Turn the starting switch OFF.
Wiring harness between BRC2 , and
R14 (female)
Between BRC2 , and chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-717

➀
20-718 HD465-7, HD605-7

➀
[DB13KK] DIRECT LINE OF RETARDER CONTROLLER BATTERY: LOWERING OF

Action code Error code Controller code Direct line of retarder controller battery • Lowering of source/input volt-
Trouble
E03 DB13KK BK age (KK)
Contents of trouble • The direct power source voltage is below 5 V.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) for grounding fault.

Disconnection in wiring har- and chassis ground
1
(Disconnection or defective 2) Disconnect connector BRC1.
Possible causes contact) 3) Insert T-adapter.
in normal state Wiring harness between battery, Voltage between
battery relay terminal B, and BRC1 BRC1 , and , 20 – 30 V

Between BRC1 and , Voltage 20 – 30 V
HD465-7, HD605-7 20-719

➀
TROUBLESHOOTING [DB19KM]
[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION

OR SETTING (KM)
Action code Error code Controller code Retarder controller wiring harness • Mistake in operation or setting
Trouble (KM)
E03 DB19KM BK (Mistake in connection or defect in wiring harness)
• The connector check signal, that is input when the starting switch is turned to the ON position, does
Contents of trouble
not agree with setting in the controller.
• The controller turns the all output circuits OFF.
Problem that
ASR)
appears on machine
• Error codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

The connector of the connector check signal is connected normally.
1 ★ Connector check signal connector: BRC3A (OPEN), BRC5A
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector BRC5A.
2
Wiring harness between BRC5A (female)
and chassis ground
Possible causes
and standard value
in normal state 3
Wiring harness between BRC3A
tween BRC3A (female) Min. 1 M Ω
and chassis ground
4 Retarder controller Wiring harness between BRC5A (female)
and chassis ground
Between BRC3A (female) and chassis
ground
20-720 HD465-7, HD605-7

➀
TROUBLESHOOTING [DB1SKQ]
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF

Action code Error code Controller code Wrong information on model selection: Disagreement of model selec-
Trouble
E03 DB1SKQ BK tion signals (KQ)
• Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or received model selection information is out of setting.
Problem that
appears on machine
Related information • Other failures are detected, too. (Error codes [DAFSKQ], [DAQAKR], DAQSKQ] are displayed.)

Possible causes Transmission controller de- ★ If the failure is not repaired by replacing the retarder controller, the
1
and standard value fective transmission controller is defective.
in normal state ★ If the failure is repaired by replacing the transmission controller, the
retarder controller is defective.
HD465-7, HD605-7 20-721

➀
TROUBLESHOOTING [DDD7KX]
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (OPT): OUT OF INPUT
SIGNAL RANGE (KX)
Action code Error code Controller code Failure in travel speed set switch system (OPT): Out of input sig-
Trouble nal range (KX)
E03 DDD7KX BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of controller • When ARSC operates, the controller releases the brake gradually.
Problem that
appears on machine

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Register (250 Ω) defective 3) Connect T-adapter.
Between RE3 (female) and Resistance 250 ± 25 Ω
3 Resistor (1,020 Ω) defective 3) Connect T-adapter.
Between RE4 (female) and Resistance 1,020 ± 102 Ω
2) Disconnect connectors BRC3A, BRC3B, ARC, RE3, and RE4.
Disconnection in wiring har- and RE3 (male) Resistance Max. 1 Ω
ness
Possible causes 4 Wiring harness between BRC3B (female)
and standard value and RE3 (male) and ARC (female)
contact)
in normal state Wiring harness between RE4 (male) and
ARC (female)
Wiring harness between RE4 (male) and
ARC (female)
2) Disconnect connectors BRC3A and BRC3B.
Between BRC3A and Voltage Approx. 5 V
5 Retarder controller defective 3) Insert T-adapter.
When set switch is ON Resistance 1,020 ± 102 Ω
When set switch is
Resistance 68 ± 6.8 Ω
Between BRC3B (fe- TOUCH UP
male) and BRC3A When set switch is
(female) Resistance 198 ± 19.8 Ω
TOUCH DOWN
When set switch is
Resistance 418 ± 41.8 Ω
CANCEL
20-722 HD465-7, HD605-7

➀
TROUBLESHOOTING [DDD7KX]
HD465-7, HD605-7 20-723

➀
TROUBLESHOOTING [DDD8KA]
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Action code Error codeController code ARSC system switch system: Disconnection (KA)
Trouble
E03 DDD8KA BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
1
Wiring harness between DPC2B (female)
and ARSC (female)
2) Replace the ARSC system switch with normal one.
ARSC system switch defec- When the ARSC system No System switch is normal
2
Possible causes tive switch is replaced with nor-
and standard value mal one, is failure repaired? Yes System switch is defective
in normal state Between HEPS (female) , and chassis
ground
2) Disconnect connector DPC1.
Turn the ARSC system
switch ON (Press it up).
DPC2B and
chassis ground Turn the ARSC system Voltage Max. 1 V
switch OFF (Press it down).
20-724 HD465-7, HD605-7

➀
TROUBLESHOOTING [DDD8KB]
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Action code Error codeController code ARSC system switch system: Short circuit (KB)
Trouble
E03 DDD8KB BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

2) Disconnect connectors ARSC and DPC2B.
1 Wiring harness be- Voltage between
tween DPC2B (fe- DPC2B (female) ,
Voltage Max. 1 V
male) and ARSC ARSC (female) and
(female) chassis ground
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec- When the ARSC system No System switch is normal
2
and standard value tive switch is replaced with nor-
in normal state mal one, is failure repaired? Yes System switch is defective
Between HEPS (female) , and chassis
ground
Turn the ARSC system
switch ON (Press it up).
DPC2B and
chassis ground Turn the ARSC system
Voltage Max. 1 V
switch OFF (Press it down).
HD465-7, HD605-7 20-725

➀
TROUBLESHOOTING [dGR2L8]
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: SEE

SEPARATE LIST (L8)
Action code Error code Controller code Failure in retarder oil temperature sensor system • See sepa-
Trouble rate list (L8)
E03 dGR2L8 BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "DGR2L8" is displayed.

Retarder brake oil tempera-
1 Brake oil temperature:
ture sensor defective Resistance 37 – 50 k Ω
Between T02 (male) 25°C
and Brake oil temperature:
Resistance 3.5 – 4.0 k Ω
100°C
2) Disconnect connectors BRC3B and T02.
Possible causes
in normal state 2 Resistance value between
BRC3B (female) , T02 (fe-
BRC3B (female) and T02 Min. 1 M Ω
male) and chassis
(female)
ground
3 Retarder controller defective Brake oil temperature:
Between BRC3B (fe- Resistance 37 – 50 k Ω
25°C
male) and BRC3A
Brake oil temperature:
(female) Resistance 3.5 – 4.0 k Ω
100°C
20-726 HD465-7, HD605-7

➀
TROUBLESHOOTING [DGR2L8]
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): SEE SEPARATE LIST (L8)
Action code Error code Controller code Brake oil temperature sensor (Rear) • See separate list (L8)
Trouble
E01 DGR2L8 BK (When ARSC is set and the ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
• When ARSC is set or the ARSC system switch is ON, error code "dGR2L8" is displayed.

ture sensor defective Resistance 37 – 50 k Ω
Resistance 3.5 – 4.0 k Ω
100°C
Possible causes
in normal state 2 Resistance value between
BRC3B (female) , T02 (fe-
BRC3B (female) and T02 Min. 1 M Ω
male) and chassis
(female)
ground
Between BRC3B (fe- Resistance 37 – 50 k Ω
25°C
male) and BRC3A
Brake oil temperature:
(female) Resistance 3.5 – 4.0 k Ω
100°C
HD465-7, HD605-7 20-727

➀
TROUBLESHOOTING [dHP4KX]
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (OPT): OUT

OF INPUT SIGNAL RANGE (KX)
Action code Error code Controller code Failure in suspension pressure sensor (FR) system (OPT): Out
Trouble of input signal range (KX)
E03 dHP4KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Problem that
appears on machine
• This failure can be checked in the monitoring function (Code: 32802, 32803)
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "DHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
Disconnection in wiring har- Wiring harness between BRC3A (female) (20)
1 and SUFR (female) (C)
Wiring harness between BRC3A (female) (16)
and SUFR (female) (A)
Wiring harness between PM6 (female) (2) and
SUFR (female) (B)
2) Disconnect connectors BRC3A SUFR and PM6.
Wiring harness between Resistance between BRC3A
2 BRC3A (female) (20) and (female) (20), SUFR (female) Min. 1 M Ω
harness
SUFR (female) (C) (C) and chassis ground
Wiring harness between Resistance between PM6
PM6 (female) (14) and (female) (2), SUFR (female) Min. 1 M Ω
Possible causes SUFR (female) (B) (B) and chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
3
Wiring harness between Voltage between BRC3A (fe-
BRC3A (female) (20) and male) (9), SUFR (female) Max. 1 V
2) Disconnect connector SUFR.
Suspension pressure sensor 4) Connect the connector.
4
(FR) defective 5) Turn the starting switch ON.
Between SUFR (B) and (A) Voltage 20 – 30 V
Between SUFR (C) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC3A.
BRC3A (20) and (16) Voltage 1.0 – 4.6 V
20-728 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-729

➄
TROUBLESHOOTING [DHP4KX]
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FR) system (OPT): Out
Trouble of input signal range (KX)
E03 DHP4KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Action of controller • Auto suspension system does not operate.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, error code "dHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
1 and SUFR (female) (C)
and SUFR (female) (A)
Wiring harness between PM6 (female) (14)
and SUFR (female) (B)
2) Disconnect connectors BRC3A, SUFR and PM6.
2 BRC3A (female) (20) and (female) (20), SUFR (female) Min. 1 M Ω
harness
PM6 (female) (2) and SUFR (female) (2), SUFR (female) Min. 1 M Ω
Possible causes (female) (B) (B) and chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
3
BRC3A (female) (20) and male) (9), SUFR (female) Max. 1 V
4
Between SUFR (B) and (A) Voltage 18 ± 3 V
2) Disconnect connectors BRC1 and BRC3A.
20-730 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-731

➄
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FL) system (OPT): Out of
Trouble input signal range (KX)
E03 dHP5KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "DHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 and SUFL (female) (C)
and SUFL (female) (A)
SUFL (female) (B)
2) Disconnect connectors BRC3A SUFLand PM6.
2 BRC3A (female) (19) and (female) (19), SUFL (female) Min. 1 M Ω
harness
SUFL (female) (C) (C) and chassis ground
PM6 (female) (2) and SUFL (female) (2), SUFL (female) Min. 1 M Ω
in normal state 2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) (20) and male) (9), SUFL (female) (C) Max. 1 V
SUFL (female) (C) and chassis ground
2) Disconnect connector SUFL.
4
Between SUFL (B) and (A) Voltage 18 ± 3 V
Between SUFL (C) and (A) Voltage 1.0 – 4.6 V
20-732 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-733

➄
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FL) system (OPT): Out of
Trouble input signal range (KX)
E03 DHP5KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Action of controller • ARSC does not operate.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, error code "dHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 and SUFL (female) (C)
and SUFL (female) (A)
SUFL (female) (B)
2) Disconnect connectors BRC3A, SUFL and PM6.
2 BRC3A (female) (19) and (female) (19), SUFL (female) Min. 1 M Ω
harness
PM6 (female) (2) and SUFL (female) (2), SUFL (female) Min. 1 M Ω
in normal state 2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) (20) and male) (9), SUFL (female) (B) Max. 1 V
SUFL (female) (C) and chassis ground
4
Between SUFL (B) and (A) Voltage 18 ± 3 V
20-734 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-735

➄
TROUBLESHOOTING [DHU2KX]
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT

SIGNAL RANGE (KX)
Action code Error code Controller code Accumulator oil pressure sensor (Front): Out of input signal
Trouble
E01 DHU2KX BK range (KX)
Contents of trouble • The signal circuit voltage of the front accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BRC1 and fuse BT3 terminal .
4) Connect the connector and fuse BT3 terminal .
Voltage between
Wiring harness between fuse BT3
BRC1 and chassis 20 – 30 V
terminal and BRC1 (female)
Disconnection in wiring har- ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCF.
and ACCF (female)
and ACCF (female)
and ACCF (female)
2) Disconnect connectors BRC3B and ACCF.
2 BRC3A (female) and (female) , ACCF (female) Min. 1 M Ω
ACCF (female) and chassis ground
and standard value
in normal state Wiring harness between Resistance between BRC1
BRC1 (female) and (female) , ACCF (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and ACCF.
3
Wiring harness between Voltage between BRC3A
BRC3A (female) and (female) , ACCF (female) Max. 1 V
2) Disconnect connector ACCF.
Front accumulator oil pres- 4) Connect the connector.
4
Between ACCF and Voltage 20 – 30 V
Between ACCF and Voltage 0.5 – 4.5 V
Between BRC1 and BRC3A Voltage 20 – 30 V
BRC3A and Voltage 0.5 – 4.5 V
20-736 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-737

➀
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Error code Controller code Accumulator oil pressure sensor (Rear): Out of input signal
Trouble
E01 DHU3KX BK range (KX)
Contents of trouble • The signal circuit voltage of the rear accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BTC1 and fuse BT3 terminal .
4) Connect the connector and fuse BT3 terminal .
Voltage between
Wiring harness between fuse BT3
BRC1 and chassis 20 – 30 V
Disconnection in wiring har- terminal and BRC1 (female)
ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCR.
and ACCR (female)
and ACCR (female)
and ACCR (female)
2) Disconnect connectors BRC3B and ACCR.
2 BRC3A (female) and (female) , ACCR (female) Min. 1 M Ω
ACCR (female) and chassis ground
and standard value
in normal state Wiring harness between Resistance between BRC1
BRC1 (female) and (female) , ACCR (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and ACCR.
3
BRC3A (female) and (female) , ACCR (female) Max. 1 V
2) Disconnect connector ACCR.
Rear accumulator oil pres- 4) Connect the connector.
4
Between ACCR and Voltage 20 – 30 V
Between ACCR and Voltage 0.5 – 4.5 V
Between BRC1 and BRC3A Voltage 20 – 30 V
BRC3A and Voltage 0.5 – 4.5 V
20-738 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-739

➀
TROUBLESHOOTING [dK11KX]
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT): OUT OF INPUT

SIGNAL RANGE (KX)
Action code Error code Controller code Failure in acceleration sensor system (OPT): Out of input signal
Trouble range (KX)
E03 dK11KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Problem that
appears on machine
• If the error code "DK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
• When ARSC is not set or the ARSC system switch is OFF, error code "DK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
Wiring harness between BRC3B (female)
and ATC3B (female)
2) Disconnect connectors BRC3B and ATC3B.
Possible causes Grounding fault in wiring Resistance value be-
and standard value 2 harness Wiring harness between BRC3B tween BRC3B (fe-
in normal state (female) and ATC3B (female) male) , ATC3B Min. 1 M Ω
(female) and chas-
sis ground
Between BRC3B (female) and chassis
Voltage 0.6 – 4.75 V
ground
20-740 HD465-7, HD605-7

➀
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT): OUT OF INPUT

SIGNAL RANGE (KX)
Action code Error code Controller code Failure in acceleration sensor system (OPT): Out of input signal
Trouble range (KX)
E03 DK11KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Action of controller • ARSC does not operate.
Problem that
appears on machine
• If the error code "dK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
• When ARSC is set and the ARSC system switch is ON, error code "dK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
and ATC3B (female)
2) Disconnect connectors BRC3B and ATC3B.
Possible causes Grounding fault in wiring Resistance value be-
and standard value 2 harness Wiring harness between BRC3B tween BRC3B (fe-
in normal state (female) and ATC3B (female) male) , ATC3B Min. 1 M Ω
(female) and chas-
sis ground
Between BRC3B (female) and chassis
Voltage 0.6 – 4.75 V
ground
HD465-7, HD605-7 20-741

➀
TROUBLESHOOTING [DK51L5]
[DK51L5] RETARDER LEVER POTENTIOMETER: SEE SEPARATE LIST (L5)

Trouble Retarder lever potentiometer: See separate list (L5)
E03 DK51L5 BK
• The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
Contents of trouble
the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
• Controls with the potentiometer signal.
• Limits the output for the solenoid to 70%.
• Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that • This failure does not have a serious effect on the machine.
appears on machine • The retarder cannot control finely.
• The retarder does not operate (The foot brake operates, however).

2) Disconnect connectors BRC2, BRC3A, BRC3B, BRC5A, RE1, and RTL.
and RE1 (female)
Wiring harness between RE1 (female) and
RTL (female)
Disconnection in wiring har- Wiring harness between BRC3A (female)
1 and RTL (female)
and RTL (female)
and RTL (female)
and RTL (female)
Wiring harness between RTL (female) and
chassis ground
2) Disconnect connectors BRC3B, and RE1, and RTL.
Possible causes Resistance value between
and standard value Wiring harness between
BRC2 (female) , RE1 (fe-
in normal state BRC2 (female) and RE1 Min. 1 M Ω
male) and chassis
(female)
ground
RE1 (female) , RTL (fe-
RE1 (female) and RTL Min. 1 M Ω
male) and chassis
(female)
ground
BRC3B (female) , RTL
BRC3B (female) and RTL Min. 1 M Ω
(female)
ground
2) Disconnect connectors BRC3B and RTL.
Wiring harness between Voltage between BRC2 (fe-
BRC2 (female) and RE1 male) , RE1 (female) Max. 1 V
Short circuit with power (female) and chassis ground
3
Wiring harness between Voltage between RE1 (fe-
RE1 (female) and RTL male) , RTL (female) Max. 1 V
Wiring harness between Voltage between BRC3B
BRC3B (female) and RTL (female) , RTL (female) Max. 1 V
20-742 HD465-7, HD605-7

➀

4 Resistor (RE1) defective 3) Connect T-adapter.
Between RE1 (male) and Resistance 250 Ω
2) Disconnect connector RTL
4) Insert the connector.
6) Check the potentiometer.
Between RTL and Voltage 4.1 – 4.8 V
Between RTL and Voltage 0.3 – 4.7 V
5 Retarder lever defective 2) Disconnect connector RTL
Between RTL (male) Lever at OFF position Resistance Max. 1 Ω

and Lever at ON position Resistance Min. 1 M Ω
Possible causes
and standard value
in normal state Between RTL (male) Lever at OFF position Resistance Min. 1 M Ω
and Lever at ON position Resistance Max. 1 Ω
2) Disconnect connectors BRC2, BRC3A, and BRC3B.
Between BRC2 and BRC3A Voltage 4.1 – 4.8 V
Between BRC3B and BRC3A Voltage 0.3 – 4.7 V
6 Retarder controller defective 2) Disconnect connector RTL.
Between BRC5A (fe- Lever at OFF position Resistance Max. 1 Ω
male) and chassis
ground Lever at ON position Resistance Min. 1 M Ω
Between BRC5A (fe- Lever at OFF position Resistance Min. 1 M Ω
male) and chassis
ground Lever at ON position Resistance Max. 1 Ω
HD465-7, HD605-7 20-743

➀
20-744 HD465-7, HD605-7

➀
[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX)

Action code Error code Controller code Dump lever potentiometer 1: Out of input signal range (KX)
Trouble
E03 DK52KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble • The signal voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V.
Action of controller • The controller recognizes the dump lever position as "HOLD".
Problem that
• The dump body does not operate.
appears on machine

2) Disconnect connectors BRC3A, BRC3B, and HSL.
Disconnection in wiring har- and HSL (female) Resistance Max. 1 Ω
ness
1 Wiring harness between BRC3B (female)
and HSL (female)
contact)
and HSL (female)
and HSL (female)
BRC3A (female) , HSL
BRC3A (female) and Min. 1 M Ω
HSL (female)
ground
BRC3B (female) , HSL
BRC3B (female) and Min. 1 M Ω
HSL (female)
ground
Possible causes
and standard value Resistance value between
BRC3B (female) , HSL
in normal state BRC3B (female) and Min. 1 M Ω
HSL (female)
ground
BRC3A (female) and (female) , HSL (female) Max. 1 V
Short circuit with power HSL (female) and chassis ground
3
BRC3B (female) and (female) , HSL (female) Max. 1 V
HSL (female) and chassis ground
BRC3B (female) and (female) , HSL (female) Max. 1 V
HSL (female) and chassis ground
2) Disconnect connector HSL.
4 Dump lever defective 5) Turn the starting switch ON.
Between HSL and Voltage 4.6 – 5.4 V
HD465-7, HD605-7 20-745

➀

in normal state 5 Retarder controller defective 5) Turn the starting switch ON.
Between BRC3A and Voltage 4.1 – 4.8 V
20-746 HD465-7, HD605-7

➀
[DK53L8] DUMP LEVER POTENTIOMETER 2: SEE SEPARATE LIST (L8)
Action code Error code Controller code Dump lever potentiometer 2: See separate list (L8)
Trouble (Out of total range of input signal voltage of lever potentiometer
E03 DK53L8 BK 1 or 2)
Contents of trouble • The total voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
Action of controller • The controller recognizes the dump lever position as "NEUTRAL".
Problem that
appears on machine
• This failure can be checked in the monitoring function (Code: 34300, 34301).
Related information
• If the error code "DK52KX" is displayed, perform troubleshooting for it.

2) Disconnect connector HSL.
Possible causes
1 Dump lever defective 5) Turn the starting switch ON.
and standard value
in normal state Between HSL and Voltage 4.6 – 5.4 V
• If the failure is not repaired by performing the troubleshooting in 1
above, the retarder controller is defective.
HD465-7, HD605-7 20-747

➀
[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code Error codeController code Body positioner sensor: Out of input signal range (KX)
Trouble
E03 DK54KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble • The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
• The controller controls dumping according to the dump level signal.
• The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that • The dump lever positioner does not function.
appears on machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the dump lever is not at FLOAT.
Related information • This failure can be checked in the monitoring function (Code: 34300, 34301, 34400, 34600).

2) Disconnect connectors BRC3A, BRC3B, and B07.
1 and B07 (female)
and B07 (female)
and B07 (female)
BRC3A (female) , B07
Grounding fault in wiring BRC3A (female) and B07 Min. 1 M Ω
2 (female) and chassis
harness (female)
ground
BRC3B (female) , B07
BRC3B (female) and B07 Min. 1 M Ω
(female)
ground
and standard value 2) Disconnect connectors BRC3A, BRC3B, and B07.
Short circuit with power Wiring harness between Voltage between BRC3A
3
source in wiring harness BRC3A (female) and B07 (female) , B07 (female) Max. 1 V
BRC3B (female) and B07 (female) , B07 (female) Max. 1 V
2) Disconnect connector B07.
4 Body positioner defective 4) Connect the connector.
Between B07 and Voltage 4.6 – 5.4 V
Between B07 and Voltage 0.3 – 4.7 V
Between BRC3A and Voltage 4.1 – 4.8 V
20-748 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-749

➀
TROUBLESHOOTING [DKD0L6]
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (OPT): SEE SEPARATE LIST (L6)

Trouble Failure in steering speed sensor (OPT): See separate list (L6)
E01 DKD0L6 BK
• Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sensor
Contents of trouble
and no signals are input.
Problem that
appears on machine

2) Disconnect connectors BRC2, BRC3A, and SR2.
1 and SR2 (female)
and SR2 (female)
and SR2 (female)
2) Disconnect connectors BRC2, BRC3A, and SR2.
BRC3A (female) , SR2
Grounding fault in wiring BRC3A (female) and Min. 1 M Ω
2 (female) and chassis
harness SR2 (female)
ground
BRC3B (female) , SR2
BRC2 (female) and SR2 Min. 1 M Ω
(female)
ground
Possible causes 2) Disconnect connector SR2.
in normal state 4) Connect the connector.
6) Turn the steering wheel slowly.
Steering speed sensor de- Between SR2 and Voltage 10 – 13 V
3
fective
2) Disconnect connector SR2.
Between SR2 and Voltage See FIG-1.
Between BRC2 and Voltage 10 – 13 V
4 Retarder controller defective 1) Turn the starting switch OFF.
6) Turn the steering wheel slowly.
Between BRC3A and Voltage See FIG-1.
20-750 HD465-7, HD605-7

➀
TROUBLESHOOTING [DKD0L6]
HD465-7, HD605-7 20-751

➀
TROUBLESHOOTING [dLt3KA]
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Error code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E01 dLt3KA BK (When ARSC is set and ARSC system switch is ON)
• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Action of controller • When ARS operates, the controller releases the brake gradually.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "dLT3KA" is displayed.

★ For details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
Possible causes Resistance Min. 1 M Ω
ground
and standard value
2) Disconnect connectors BRC3A and CN5.
ness
3 Wiring harness between BRC3A (female)
and CN5 (female)
contact)
and CN5 (female)
2) Disconnect connectors BRC3A and ATC3A.
4 Retarder controller defective 3) Connect T-adapter.
Between BRC3A (female) and Resistance 500 – 1,000 Ω
20-752 HD465-7, HD605-7

➀
TROUBLESHOOTING [dLT3KA]
[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Error code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E03 dLT3KA BK (When ARSC is not set or ARSC system switch is OFF)
• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, error code "dLT3KA" is displayed.

★ For details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
ground
and standard value
2) Disconnect connectors BRC3A and CN5.
ness
3 Wiring harness between BRC3A (female)
and CN5 (female)
contact)
and CN5 (female)
2) Disconnect connectors BRC3A and ATC3A.
Between BRC3A (female) and Resistance 500 – 1,000 Ω
HD465-7, HD605-7 20-753

➀
TROUBLESHOOTING [DW35KZ]
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Error code Controller code Failure in output system of auto suspension solenoid 1 (OPT)
Trouble (Disconnection, grounding fault, short circuit): Disconnection or
E01 DW35KZ BK short circuit (KZ)
• When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to auto suspension solenoid 1 OFF.
Problem that
• The auto suspension system does not operate.
appears on machine

2) Disconnect connector S04.
Auto suspension solenoid 1 3) Insert T-adapter.
1
defective Between S04 (female) (1) and (2) Resistance 15 – 35 Ω
Between S04 (female) (1), (2) and chassis
ground
Possible causes 2) Disconnect connectors BRC1 and S04.
2 Wiring harness between BRC1 (female) (1)
and S04 (female) (1)
contact)
Wiring harness between S04 (female) (2) and
chassis ground
Between BRC1 (female) (1) and chassis
Resistance 15 – 20 Ω
ground
20-754 HD465-7, HD605-7

➄
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT)

Action code Error code Controller code Failure in output system of auto suspension solenoid 2 (OPT)
Trouble (Disconnection, grounding fault, short circuit): Disconnection or
E01 DW36KZ BK short circuit (KZ)
• When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to auto suspension solenoid 2 OFF.
Problem that
• The auto suspension system does not operate.
appears on machine

2) Disconnect connector S05.
Auto suspension solenoid 2 3) Insert T-adapter.
1
defective Between S05 (female) (1) and (2) Resistance 15 – 35 Ω
Between S05 (female) (1), (2) and chassis
ground
Possible causes 2) Disconnect connectors BRC1 and S05.
and S05 (female) (1)
contact)
Wiring harness between S05 (female) (2) and
chassis ground
Between BRC1 (female) (2) and chassis
ground
HD465-7, HD605-7 20-755

➄
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)

Action code Error code Controller code Failure in kick-out solenoid output system (D_OUT3) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E01 DW72KZ BK cuit (KZ)
• When the output to the dump lever kick-out solenoid circuit is ON, a too large current flows or any cur-
Contents of trouble
rent does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to the dump lever kick-out solenoid OFF.
Problem that
• Detent lock is not applied to the dump lever.
appears on machine

2) Disconnect connectors BRC1 and LK0.
ness
1 Wiring harness between LK0 (female) and
chassis ground
contact)
and LK0 (female)
2) Disconnect connectors BRC1 and LK0.
2
Possible causes source in wiring harness Voltage between
and standard value Wiring harness between BRC1 BRC1 (female) ,
Max. 1 V
in normal state (female) and LK0 (female) LK0 (female) and
chassis ground
2) Disconnect connector LK0.
Dump lever kick-out sole- 3) Connect T-adapter.
3
noid defective Between LK0 (male) and Resistance 39 Ω ± 5%
Between LK0 (male) , and chassis
ground
2) Disconnect connector LK0.
Between BRC1 (female) and chassis
Resistance 39 Ω ± 5%
ground
20-756 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-757

➀
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)

Action code Error code Controller code Failure in hoist select valve output system (D_OUT5) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E03 DW73KZ BK cuit (KZ)
• When the output to the dump lever select valve solenoid circuit is ON, a too large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
• The controller turns the output to the dump lever select valve solenoid OFF.
• The controller turns the output to the dump lever EPC valve solenoid OFF.
Problem that
appears on machine

2) Disconnect connectors BRC1 and HSOL.
ness
1 Wiring harness between HSOL (female)
and chassis ground
contact)
and HSOL (female)
2) Disconnect connectors BRC1 and HSOL.
2
Possible causes source in wiring harness Voltage between
and standard value Wiring harness between BRC1 BRC1 (female) ,
Max. 1 V
in normal state (female) and HSOL (female) HSOL (female) and
chassis ground
2) Disconnect connector HSOL.
Dump lever select valve so- 3) Connect T-adapter.
3
lenoid defective Between HSOL (male) and Resistance 15 – 35 Ω
Between HSOL (male) , and chassis
ground
2) Disconnect connector HSOL.
Between BRC1 (female) and chassis
ground
20-758 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-759

➀
TROUBLESHOOTING [DK11K4]
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: UNCONTROLLABLE (K4)
Action code Error code Controller code Proportional solenoid pressure reducing valve of rear wheel: Un-
Trouble
E03 DK11K4 BK controllable (K4)
Contents of trouble • The proportional solenoid pressure reducing valve does not return (does not move).
Action of controller • Resets the retarder solenoid output.
Problem that
• The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
• The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional
• Check proportional solenoid pressure reducing valve of rear wheel
1 solenoid pressure reducing
and repair or replace it, if it has abnormality (mechanical failure).
valve of rear wheel
1) Turn starting switch OFF.
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 Ω
male) (1) and (2) Oil pressure OFF Resistance Min. 1 M Ω
2) Disconnect connector BRC5A and RESW.
Grounding fault in wiring 4) Connect connector.
3 5) Turn starting switch ON.
harness
Possible causes
and standard value Wiring harness between Resistance between BRC5A
in normal state BRC5A (female) (4) and (female) (4), RESW (female) Max. 1 Ω
RESW (female) (1) (1) and chassis ground
2) Disconnect connector BRC5A and RESW.
Short circuit with power 4) Connect connector.
BRC5A (female) (4) and male) (4), RESW (female) Max. 1 V
2) Disconnect connector BRC5A and BRC3A.
5 Defective retarder controller 4) Connect connector.
5) Turn starting switch ON.
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
and BRC3A (16) Oil pressure OFF Voltage 20 – 30 V
20-759-1 HD465-7, HD605-7

➄
TROUBLESHOOTING [DK11K4]
HD465-7, HD605-7 20-759-2

➄
TROUBLESHOOTING [DX11KA]
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL
(A_OUT2): DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Disconnection
E03 DX11KA BK (KA)
• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, any current does not
Contents of trouble
flow.
Action of controller • The controller turns the output to the rear brake pressure reducing valve solenoid OFF.
Problem that
• The retarder (rear brake) does not operate.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 33800, 33801).

2) Disconnect connector RETV.
Rear brake pressure reduc- 3) Insert T-adapter.
1
ing valve solenoid defective Between RETV (female) (1) and (2) Resistance 10 – 30 Ω
Between RETV (female) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and RETV.
and RETV (female) (1).
contact)
Wiring harness between BRC2 (female) (17)
and RETV (female) (1).
2) Disconnect connector BRC.
Between BRC2 (female) (7) and (17) Resistance 10 – 30 Ω
20-760 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX11KB]
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

(A_OUT2): SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KB BK (KB)
• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, a too large current
Contents of trouble
flows.
Problem that
appears on machine

1
ground
2) Disconnect connectors BRC2 and RETV.
Possible causes 3) Connect T-adapter.
and standard value Resistance value be-
in normal state Wiring harness between BRC2
Grounding fault or short cir- tween BRC2 (female)
2 (female) (7) and RETV (female) Min. 1 M Ω
cuit in wiring harness (9), RETV (female) (1)
(1).
and chassis ground.
Wiring harness between BRC (female) (7) and RETV (fe-
male) (1) and wiring harness between BRC (female) (17) Min. 1 M Ω
and RETV (female) (2)
HD465-7, HD605-7 20-761

➄
TROUBLESHOOTING [DX11KY]
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

(A_OUT2): SHORT CIRCUIT WITH POWER LINE (KY)
Action code Error code Controller code Grounding fault in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KY BK with power line (KY)
• While the output to the rear wheel pressure reducing valve solenoid circuit is OFF, some current is flow-
Contents of trouble
ing.
Problem that
appears on machine

1
ground

and standard value 2) Disconnect connectors BRC2 and RETV.
2 Voltage between
source in wiring harness Wiring harness between BRC2
BRC2 (female) (7),
(female) (7) and RETV (female) Max. 1 V
RETV (female) (1) and
(1).
chassis ground.
20-762 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX11MA]
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: MALFUNCTION (MA)
Action code Error code Controller code Proportional solenoid pressure reducing valve of rear wheel:
Trouble
E03 DX11MA BK Malfunction (MA)
Contents of trouble • The proportional solenoid pressure reducing valve does not operate (does not move).
Action of controller • Resets the retarder solenoid output.
Problem that
• The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
• The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional sole- • Check the proportional solenoid pressure reducing valve of rear
1 noid pressure reducing wheel and repair or replace it, if it has abnormality (mechanical fail-
valve of rear wheel ure).
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 Ω
male) (1) and (2) Oil pressure OFF Resistance Min. 1 M Ω
Possible causes
and standard value 1) Turn starting switch OFF.
in normal state 2) Disconnect connector BRC5A and RESW.
3
ness Wiring harness between Resistance between BRC5A
BRC5A (female) (4) and (female) (4), RESW (female) Max. 1 Ω
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
and BRC3A (16) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-762-1

➄
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of hoist EPC valve (A_OUT3):
Trouble
E03 DX13KA BK Disconnection (KA)
Contents of trouble • When the output to the dump EPC solenoid circuit is ON, any current does not flow.
• The controller turns the output to the dump select valve solenoid OFF.
• The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

2) Disconnect connector HEPC.
Dump EPC valve solenoid
1
defective Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
Between HEPC (female) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and HEPC.
and standard value
in normal state
ness
and HEPC (female) (1).
contact)
and HEPC (female) (1).
19. Between BRC2 (female) (10) and (20) Resistance 15 – 20 Ω
HD465-7, HD605-7 20-763

➄
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT (KB)
Action code Error code Controller code Grounding fault in output circuit of hoist EPC valve (A_OUT3):
Trouble Short circuit (KB)
E03 DX13KB BK
Contents of trouble • When the output to the dump EPC valve solenoid circuit is ON, a too large current flows.
Action of controller • The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid
1 Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
defective
ground
and standard value
Grounding fault or short cir- (female) (10) and HEPC (female) tween BRC2 (female) Min. 1 M Ω
2 (10), HEPC (female)
cuit in wiring harness (1).
(1) and chassis ground.
Wiring harness between BRC (female) (10) and HEPC (fe-
male) (1) and wiring harness between BRC (female) (20) Min. 1 M Ω
and HEPC (female) (2)
20-764 HD465-7, HD605-7

➄
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT WITH POWER LINE (KY)
Action code Error code Controller code Short circuit in output circuit of hoist EPC valve (A_OUT3): Short
Trouble
E03 DX13KY BK circuit with power line (KY)
Contents of trouble • While the output to the dump EPC valve solenoid circuit is OFF, some large current is flowing.
• The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid 3) Insert T-adapter.
1
defective Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
ground
and standard value Short circuit with power Voltage between
source in wiring harness BRC2 (female) (10),
2 (female) (10) and HEPC (female) Max. 1 V
(Contact with power source HEPC (female) (1) and
(1).
wiring harness) chassis ground.
Voltage between
Wiring harness between BRC2
BRC2 (female) (20),
(female) (20) and HEPC (female) Max. 1 V
HEPC (female) (2) and
(2).
chassis ground.
HD465-7, HD605-7 20-765

➄
20-766 HD465-7, HD605-7

➀
TROUBLESHOOTING BK-1
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY

a) When the parking brake switch is set in the OFF position, the parking brake is not released
Action code Error code Controller code Parking brake does not operate normally
Trouble a) When the parking brake switch is set in the OFF position, the
Not set Not set BK parking brake is not released
Contents of trouble • When the parking brake switch is set in the OFF position, the parking brake is not released.
Problem that
• When the parking brake switch is set in the OFF position, the parking brake is not released.
appears on machine
• Before performing the troubleshooting, check that fuse (BT4) is not broken. (If the fuse is broken,
Related information check its wiring harness for grounding fault.)

Parking brake switch
When parking brake switch (R33) No
(R33) is normal
is disconnected, does parking
brake operate? Parking brake switch
Yes
(R33) is defective
Parking brake switch defec- 3) Connect T-adapter.
1
tive Set the parking brake switch
Between R33 Resistance Min. 1 M Ω
in PARK.
(male) and
Set the parking brake switch
in OFF.
Between R33 Resistance Max. 1 Ω
in PARK.
(male) and
in OFF.
2) Disconnect connector PSOL
Parking brake solenoid de- 3) Connect T-adapter.
2
fective Between PSOL (male) and Resistance 30 – 50 Ω
Between PSOL (male) , and chassis
and standard value ground
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective
3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
tween and .
Apply 24 V between
tween and .
HD465-7, HD605-7 20-767

➀

2) Disconnect connectors R19, R33, PSOL, fuse BT4 .
Wiring harness between fuse BT4 and R19
Possible causes Disconnection in wiring har- (female) , R33 (female) Resistance Max. 1 Ω
4 Wiring harness between R19 (female) ,
in normal state (Disconnection or defective Resistance Max. 1 Ω
and R33 (female)
contact)
PSOL (female)
Wiring harness between PSOL (female)
and chassis ground
20-768 HD465-7, HD605-7

➀
b) When the parking brake switch is set in the PARK position, the parking brake does not work
Action code Error code Controller code Parking brake does not operate normally
Trouble b) When the parking brake switch is set in the PARK position, the
Not set Not set Not set parking brake does not work
Contents of trouble • When the parking brake switch is set in the PARK position, the parking brake does not work.
Problem that
• When the parking brake switch is set in the PARK position, the parking brake does not work.
appears on machine

Between R33 Resistance Min. 1 M Ω
in PARK.
Parking brake switch defec- (male) and
1 Set the parking brake switch
tive Resistance Max. 1 Ω
in OFF.
Between R33 Resistance Max. 1 Ω
in PARK.
(male) and
in OFF.
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective

and standard value 2) Disconnect connector R19.
in normal state 3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
tween and .
Apply 24 V between
tween and .
2) Disconnect connectors R33 and PSOL.
3 Voltage between R33
Wiring harness between R33 (fe- (female) , PSOL (fe-
Max. 1 Ω
male) and PSOL (female) male) and chassis
ground
HD465-7, HD605-7 20-769

➀
20-770 HD465-7, HD605-7

➀
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE

NORMALLY
Action code Error code Controller code Retarder brake oil temperature gauge does not operate normally
Trouble
Not set Not set Not set (When ARSC is not set or ARSC system switch is OFF)
Contents of trouble • The signal circuit voltage of the retarder brake oil temperature gauge is below 0.75 V.
Problem that • This failure does not have a serious effect on the machine.
appears on machine • When ARSC is set or the ARSC system switch is ON, error code "dGR2L8" is displayed.

ture gauge defective Resistance 37 – 50 kΩ
Resistance 3.5 – 4.0 kΩ
100°C
and standard value Short circuit with power 4) Turn the starting switch ON.
in normal state 2
Wiring harness between BRC3B BRC3B (female) ,
Max. 1 V
(female) and T02 (female) T02 (female) and
chassis ground
Between BRC3A (fe- Resistance 37 – 50 kΩ
25°C
male) and BRC3A
(female) Brake oil temperature:
Resistance 3.5 – 4.0 kΩ
100°C
HD465-7, HD605-7 20-771

➀
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED

(WHEN MACHINE IS NOT INCLINED MORE THAN 15°)
Action code Error code Controller code Inclination alarm is turned ON when dump body is raised
Trouble
Not set Not set Not set (When machine is not inclined more than 15°)
• The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
Contents of trouble
more than 15°)
Problem that • The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
appears on machine more than 15°)
• If the inclination alarm is turned ON while the machine is incline more than 15°, it is not defective (it is
Related information normal).

2) Disconnect connector SR3.
1 Inclination sensor defective
Inclination is below 15° Resistance Max. 1 Ω
Between SR3 (male)
Inclination is 15° or
and Resistance Min. 1 M Ω
more
Possible causes Disconnection in wiring har- 2) Disconnect connectors BRC5A and SR3.
and SR3 (female)
Between BRC5A (fe- Inclination is below 15° Resistance Max. 1 Ω
male) and chassis Inclination is 15° or
ground Resistance Min. 1 M Ω
more
20-772 HD465-7, HD605-7

➀
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED
Action code Error code Controller code Touch up/down and cancellation cannot be performed.
Trouble
Not set Not set Not set (When ARSC is set and ARSC system switch is ON)
Contents of trouble • Touch up/down and cancellation cannot be performed.
Problem that
• Touch up/down and cancellation cannot be performed.
appears on machine
Related information • If error code "DDD7KX" is displayed, perform troubleshooting for it.

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective

2 Register (250 Ω) defective 3) Connect T-adapter.
Between RE3 (female) and Resistance 250 ± 25 Ω
3 Resistor (1,020 Ω) defective 3) Connect T-adapter.
Between RE4 (female) and Resistance 1,020 ± 102 Ω

Disconnection in wiring har- 2) Disconnect connectors BRC3A, ARC, and RE4.
Possible causes ness 3) Connect T-adapter.
4
and standard value (Disconnection or defective
in normal state contact) Resistance Max. 1 Ω
and ARC (female)
4) Connect the connectors.
Between BRC3A and Voltage Approx. 5 V
5 Retarder controller defective 2) Disconnect connectors BRC3A and BRC3B.
When set switch is ON Resistance 1,020 ± 102 Ω
Between When set switch is TOUCH
BRC3B (fe- Resistance 68 ± 6.8 Ω
UP
male) and
When set switch is TOUCH
BRC3A (fe- Resistance 198 ± 19.8 Ω
male) DOWN
When set switch is CANCEL Resistance 418 ± 41.8 Ω
HD465-7, HD605-7 20-773

➀
20-774 HD465-7, HD605-7

➀
TROUBLESHOOTING FOR PAYLOAD
METER SYSTEM (CARD TYPE)
(LC MODE)
Electrical system diagram related to payload meter ................................................................................... 20-802

Service codes of payload meter (card type) and contents of self-diagnosis ....................................... 20-804
Information in troubleshooting table........................................................................................................ 20-807
Trouble code table .................................................................................................................................. 20-808
LC- 1 When starting switch is turned ON, any item is not displayed.................................................... 20-809
LC- 2 After starting switch is turned ON, all external pilot lamps do not light up.................................. 20-811
LC- 3 External lamps light up while condition for lighting is not set...................................................... 20-814
LC- 4 Lighting level of external pilot lamps is abnormal ....................................................................... 20-816
LC- 5 Cycle data and engine ON/OFF data not recorded
(charge level signal system: judges that engine is stopped) ...................................................... 20-818
LC- 6 Calibration cannot be performed and displayed clock does not conform to condition
(shift lever "N" position signal system) ....................................................................................... 20-819
LC- 7 Displayed logic is abnormal........................................................................................................ 20-821
a) When loaded dump truck starts traveling, "0" is kept displayed ........................................... 20-821
b) After loaded dump truck start traveling, display of odometer does not increase .................. 20-821
c) When travel speed exceeds limit speed, "SP:SP" does not go off........................................ 20-821
d) Integrated pay load is not displayed ..................................................................................... 20-822
e) Displayed and saved pay load is not correct ........................................................................ 20-823
LC- 8 Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in
"FLOAT" position while truck is not dumping)............................................................................. 20-824
LC- 9 Payload meter displays "F:09" (lowering of internal backup battery voltage) ............................. 20-826
LC-10 Payload meter displays " :FULL" (data saving memory is full) ................................................ 20-826
LC-11 Payload meter displays "F-20" : failure in power source of suspension pressure sensor and
clinometer system....................................................................................................................... 20-827
LC-12 Payload meter displays "F-21" – "F-24" : disconnection or grounding fault in suspension
sensor signal system .................................................................................................................. 20-829
LC-13 Payload meter displays "F-25" – "F-28" : short circuit with power source in suspension
sensor signal system .................................................................................................................. 20-832
LC-14 Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) ... 20-834
LC-15 Payload meter displays "F:43" – "F:45" (short circuit with power source in external pilot lamp
relay system) .............................................................................................................................. 20-835
LC-16 Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) ........... 20-837
LC-17 External pilot lamp indicates forecast while truck is not being loaded or clock is displayed
while truck travels for 160 m after it is loaded ............................................................................ 20-839
LC-18 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal
system ........................................................................................................................................ 20-840
LC-19 Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal
system ........................................................................................................................................ 20-842
LC-20 Payload meter displays "F:18" (disconnection in charge level signal system) ........................... 20-844
HD465-7, HD605-7 20-801

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
HD465-7, HD605-7 20-803

➁
SERVICE CODES OF PAYLOAD METER (CARD TYPE)
TROUBLESHOOTING AND CONTENTS OF SELF-DIAGNOSIS
SERVICE CODES OF PAYLOAD METER (CARD TYPE) AND CONTENTS OF SELF-

DIAGNOSIS
The following are displayed on the display unit of Payload Meter (Card type). (They are not displayed on the
monitor panel.)
Priority of Contents Service code External pilot lamps
display
b-FL lighting up All lighting up
Dump lever is not in FLOAT position (Truck is not
1
dumping)
b-FL lighting up —
2 Memory card is not inserted Cd flashing —
3 Backup battery voltage is lowered F-09 flashing —
Cycle data memory is FULL
Engine ON/OFF data is FULL

See (*1) on next
4 —
page.
Abnormality warning data memory is FULL
Data memory of integrated pay load and total number
of cycle is FULL
5 Disconnection of terminal R F-18 flashin All flashing
6 Abnormality in sensor power source (18 V) F-20 flashin All flashing

Short circuit with chassis ground or disconnection in
7 front left suspension pressure sensor system F-21 flashin All flashing
8 Short circuit with chassis ground or disconnection in F-22 flashin All flashing
front right suspension pressure sensor system
9 F-23 flashin All flashing
rear left suspension pressure sensor system
10 rear right suspension pressure sensor system F-24 flashin All flashing
11 Short circuit with power source in front left suspension F-25 flashin All flashing
Short circuit with power source in front right suspension
12 pressure sensor system F-26 flashin All flashing
Short circuit with power source in rear left suspension
14 Short circuit with power source in rear right suspension F-28 flashin All flashing
Short circuit with chassis ground or disconnection in cli-
nometer system
16 Short circuit with power source of clinometer system F-32 flashin All flashing
Calibration has not been performed or RAM is abnor-
17 F • CAL flashin All flashing
mal
Related lamps
18 Short circuit in external pilot lamp G relay F-43 flashin While stopped: Kept lighted up
While traveling: Turned OFF
Other lamps
19 Short circuit in external pilot lamp Y relay F-44 flashin
While loading: Normal operation
While stopped without loading:
20 Short circuit in external pilot lamp R relay F-45 flashin Flashing
While traveling: Turned OFF
Pay load in cycle data is inaccurate [See (*2) in page
21 L. bad flashin —
20-806]
22 Higher than limit speed SP : SP flashin —
F-71 flashin
F-73 flashin
F-80 flashin
F-81 flashin
F-91 flashin
23 Communication defective or wrong option code setting F-92 flashin —
F-93 flashin
F-94 flashin
F-95 flashin
F-96 flashin
F-97 flashin
F-98 flashin
20-804 HD465-7, HD605-7

➀
(*1) Alarm displayed when memory is FULL abnormality/warning data are deleted
1. Cycle data from the oldest one. (The alarm of "2)"
1) If the number of saved cycles reaches above is maintained.)
2600 (the remaining capacity is 300
cycles or less), the following is repeated. 4. Integrated pay load/Total number of
L : FUL flashes 7 times. cycles data
: flashes 1 time. 1) If the total number of cycles reaches
2) If the number of saved cycles reaches 9994 (the remaining capacity is 5 cycles
2900 (the remaining capacity is 0 cycle), or less) or the difference between the
the following is repeated. saved integrated pay load and 999900
L : FUL lights up (for 3 seconds). tons (upper limit) becomes 5 times the
: flashes 1 time. rated hauling capacity, the following is
3) If the number of saved cycles exceeds repeated.
2900, the new cycles are saved as H : FUL flashes 7 times (for 3 seconds).
2901st cycle, 2902nd cycle ---. Each : flashes 1 time.
time the new cycle is saved, however, 2) If the total number of cycles reaches
the cycle data are deleted from the oldest 9997 (the remaining capacity is 2 cycles
one. (The alarm of "2)" above is main- or less) or the difference between the
tained.) saved integrated pay load and 999900
tons (upper limit) becomes 5 times the
2. Engine ON/OFF data rated hauling capacity, the following is
1) If the number of saved ON/OFF times repeated.
reaches 105 (the remaining capacity is H : FUL lights up (for 3 seconds).
10 times or less), the following is : flashes 1 time.
repeated 2 times and then goes off. 3) If the total number of cycles reaches
E : FUL flashes 7 times (for 3 seconds). 9999 or the saved integrated pay load
: flashes 1 time. exceeds 999900 tons, both of the inte-
2) If the number of saved ON/OFF times grated pay load and total number of
reaches 115 (the remaining capacity is 0 cycles are cleared to 0, and then they are
time), the following is repeated 2 times integrated again. (The display unit dis-
and then goes off. plays the operating time normally again.)
E : FUL lights up (for 3 seconds).
: flashes 1 time. 5. For the method of resetting the data in 1 – 3
3) If the number of saved ON/OFF times above when they become FULL, see "8.3
exceeds 115, the new ON/OFF times are Operator check mode" in the instruction
saved as 116th time, 117th time ---. manual for Payload Meter (Card type).
Each time the new ON/OFF time is Once the data in 4 becomes FULL, it is not
saved, however, the engine ON/OFF reset until it is cleared to 0 automatically. For
data are deleted from the oldest one. the method of clearing this data to 0 forcibly
before it becomes FULL, see "8.2 Forcible
3. Abnormality/Warning data display of integrated pay load/total number of
1) If the number of saved abnormalities/ cycles" in the instruction manual for Payload
warnings reaches 220 (the remaining Meter .
capacity is 10 abnormalities/warnings or
less), the following is repeated. 6. As for the order of display, any priority is not
E : FUL flashes 7 times (for 3 seconds). given to the items in 1 – 4 above. If multiple
: flashes 1 time. data become FULL simultaneously, they are
2) If the number of saved abnormalities/ displayed while the dump truck is not being
warnings reaches 230 (the remaining loaded.
capacity is 0 abnormality/warning), the
following is repeated.
E : FUL lights up (for 3 seconds).
: flashes 1 time.
3) If the number of saved abnormalities/
warnings exceeds 230, the new abnor-
malities/warnings are saved as 231st
abnormality/warning, 232nd abnormality/
warning ---. Each time the new abnor-
mality/warning is saved, however, the
HD465-7, HD605-7 20-805

➀
(*2) Inaccurate pay load in cycle data

1. The payload meter constantly senses the
pay load by the signals from the suspension
pressure sensor. The sensed pay load
becomes a little inaccurate during and just
after loading because of the dynamic friction
of the suspension. To save the pay load
more accurately, the payload meter senses
and saves the pay load just before dumping
after the dynamic friction of the suspension
during loading is canceled by loaded travel.
(The payload meter saves the payload meter
as a part of the cycle data.)
2. Accordingly, if the load is dumped (if the

dump lever is operated) before pitching of
the machine body stops, the payload meter
may save the pay load inaccurately.
3. When the dump truck is braked sharply or

stopped by chocks in the dumping place, the
pay load may be saved inaccurately.
4. If the load is dumped before the dump truck

stops pitching for the above reasons, the
payload meter displays "Inaccurate pay load
in cycle data" in the abnormality/warning
items list to call the operator's attention. The
pay load sensed in this case is saved, how-
ever.
20-806 HD465-7, HD605-7

➀


panel panel panel
Problem that
appears on machine

1
• Disconnection
• Short circuit
3
side.
side.
5
side.
HD465-7, HD605-7 20-807

➀

TROUBLE CODE TABLE




MW Sliding
NS Overheat
20-808 HD465-7, HD605-7

➀
TROUBLESHOOTING LC-1
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED

Trouble When starting switch is turned ON, any item is not displayed
Not set Not set Not set
Contents of trouble • When the starting switch is turned ON, any item is not displayed.
Problem that
• When the starting switch is turned ON, any item is not displayed.
appears on machine
• Before performing the troubleshooting, check that fuse BT2 circuit breaker (80 A) is not broken.
Related information
(If the fuse is broken, check its wiring harness for grounding fault.)

When LC GDL relay (R10) is re- No Relay (R10) is normal
placed, is failure repaired? Yes Relay (R10) is defective
3) Check the relay.
1 LC GDL relay (R10) defective Between R10 (male) and Resistance 200 – 400 Ω
3) Check the relay.
4) Apply voltage between R10 (male) and
Apply 24 V between
Possible causes and Do not apply 24 V be-
and standard value Resistance Min. 1 M Ω
tween and .
in normal state
2) Disconnect connector connectors R10 and fuse BT2 .
Wiring harness between battery relay terminal
Disconnection in wiring har- M, fuse BT2 Resistance Max. 1 Ω
and R10 (female) and
ness
2 Wiring harness between R10 (female) and
chassis ground
contact)
Wiring harness between PM5 (female) and
R10 (female)
chassis ground
2) Disconnect connector PM5.
3 Payload meter defective 4) Connect the connector.
Between PM5 and Voltage 20 – 30 V
HD465-7, HD605-7 20-809

➀
20-810 HD465-7, HD605-7

➀
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO
NOT LIGHT UP
Action code Error code Controller code After starting switch is turned ON, all external pilot lamps do not
light up
Trouble
Not set Not set Not set (Perform troubleshooting with shift lever in N and starting switch
in ON)
• After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
Contents of trouble
shift lever in N and starting switch in ON.)
Problem that • After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
appears on machine shift lever in N and starting switch in ON.)
• Check that any bulb is not broken.
• If there is grounding fault between the fuse and shift lever switch terminal N (on the power supply side),
Related information error code "DF10KA" related to the transmission controller is displayed.
• Before performing the troubleshooting, check that fuse BT2 is not broken. (If the fuse is broken,
check its wiring harness for grounding fault.)

1 Breakage of bulb Any bulb must not be broken.
When payload meter relay (R40) is No Relay (R40) is normal
replaced, is failure repaired? Yes Relay (R40) is defective
3) Check the relay.
Payload meter relay (R40) 1) Turn the starting switch OFF.

2 2) Disconnect connector R40.
defective
3) Check the relay.
4) Apply voltage between R40 (male) and
Apply 24 V between
Possible causes tween and .
and standard value Apply 24 V between
tween and .
2) Disconnect connector connectors SF1, R40, PM5, R43, R44, R45,
B1, B2, and B3.
1) Any lamp does not light up.
Wiring harness between SF1 (female) and
R40 (female)
ness Wiring harness between R40 (female) and
(Disconnection or defective chassis ground
contact) 2) Specific lamps do not light up.
and R43 (female)
and R44 (female)
and R45 (female)
HD465-7, HD605-7 20-811

➀

G (female)
A (female)
Disconnection in wiring har- Wiring harness between R45 (female) and
ness R (female)
3
(Disconnection or defective Wiring harness between B1 (female) and
chassis ground
Wiring harness between B2 (female) and
chassis ground
Wiring harness between B3 (female) and
chassis ground
2) Disconnect connectors SF1, R40, PM5, R43, R44, and R45.
1) Any lamp does not light up.
★ In this case, fuse BT3 (for supplying power to shift switch N) is
broken.
Wiring harness between SF1 (fe- tween SF1 (female)
Possible causes Min. 1 M Ω
and standard value male) and R40 (female) , R40 (female)
2) Specific lamps do not light up.
harness
Wiring harness between PM5 (fe- tween PM5 (female)
Max. 1 Ω
male) and R43 (female) , R43 (female)
and chassis ground
Max. 1 Ω
and chassis ground
Max. 1 Ω
and chassis ground
5 Payload meter defective 5) Turn the starting switch ON.
20-812 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-813

➀
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET

Trouble External lamps light up while condition for lighting is not set
Contents of trouble • External lamps light up while condition for lighting is not set.
Problem that
• External lamps light up while condition for lighting is not set.
appears on machine

2) Replace R43, R44, and R45 with normal ones.
(Replace only the defective relays with normal ones.)
When payload meter lamp relays Relays (R43), (R44),
No
(R43), (R44), and (R45) is re- and (R45) are normal
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 2) Disconnect connectors R43, R44, and R45.
1 (R43), (R44), and (R45) de- 3) Check the relays.
fective
Between R43, R44, and R45 and Resistance 200 – 400 Ω
2) Disconnect connectors R43, R44, and R45.
3) Check the relays.
4) Apply voltage between R43, R44, and R45 and .
Apply 24 V between
Between R43, R44, and .
Possible causes and R45 and . Do not apply 24 V be-
and standard value Resistance Min. 1 M Ω
tween and .
in normal state
2) Disconnect connectors SF1, R40, R43, R44, and R45.
Voltage between SF1
Wiring harness between SF1 (fe- (female) , R40 (fe-
Max. 1 V
male) and R40 (female) male) and chassis
ground
Voltage between PM5
Short circuit with power Wiring harness between R40 (fe- (female) , R43 (fe-
2 Max. 1 V
source in wiring harness male) , and R43 (female) male) and chassis
ground
Voltage between PM5
Wiring harness between R40 (fe- (female) , R44 (fe-
Max. 1 V
male) , and R44 (female) male) and chassis
ground
Voltage between PM5
Wiring harness between R40 (fe- (female) , R45 (fe-
Max. 1 V
male) , and R45 (female) male) and chassis
ground
20-814 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-815

➀
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL

Trouble Lighting level of external pilot lamps is abnormal
Contents of trouble • Lighting level of external pilot lamps is abnormal.
Problem that
• Lighting level of external pilot lamps is abnormal.
appears on machine
Related information • If this phenomenon is stopped by performing calibration again, it is not a failure.

4) Set the shift lever in N.
No
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 1) Turn the starting switch OFF.
1 (R43), (R44), and (R45) de- 2) Disconnect connectors R43, R44, and R45.
fective 3) Check the relays.
Between R43, R44, and R45 and Resistance 200 – 400 Ω
Apply 24 V between
and R45 and . Do not apply 24 V be-
tween and .
Possible causes
in normal state 2) Disconnect connectors PM5, R43, R44, and R45.
Disconnection in wiring har- Wiring harness between PM5 (female) and
2 R43 (female)
R44 (female)
R45 (female)
2) Disconnect connectors R40, R43, R44, R45, G, A, and R.
Voltage between R43
Wiring harness between R43 (fe- (female) , G (fe-
Max. 1 V
male) and G (female) male) and chassis
ground
3 Voltage between R44
Wiring harness between R44 (fe- (female) , A (fe-
Max. 1 V
male) and A (female) male) and chassis
ground
Voltage between R45
Wiring harness between R45 (fe- (female) , R (fe-
Max. 1 V
male) and R (female) male) and chassis
ground
20-816 HD465-7, HD605-7

➀

in normal state 5 Payload meter defective 5) Turn the starting switch ON.
HD465-7, HD605-7 20-817

➀
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED

(CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED)
Action code Error code Controller code Cycle data and engine ON/OFF data not recorded
Trouble
Not set Not set Not set (Charge level signal system: Judges that engine is stopped)
• Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
Contents of trouble
is stopped.)
Problem that • Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
appears on machine is stopped.)
Related information • If the engine ON/OFF data are recorded, perform troubleshooting of LC-7.

Disconnection in wiring har- 3) Insert T-adapter.
ness 4) Connect the connector.
1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) and alternator terminal R and chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 and chassis ground Voltage Min. 5 V
20-818 HD465-7, HD605-7

➀
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT

CONFORM TO CONDITION
(SHIFT LEVER "N" POSITION SIGNAL SYSTEM)
Action code Error code Controller code Calibration cannot be performed and displayed clock does not
Trouble conform to condition
Not set Not set Not set (Shift lever "N" position signal system)
• Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
Contents of trouble
position signal system)
Problem that • Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
appears on machine position signal system)
Related information • Check that the external pilot lamp operates as described in the operation manual.

When transmission neutral relay No Relay (R02) is normal
(R02) is replaced with normal one,
is failure repaired? Yes Relay (R02) is defective
Transmission neutral relay
1
Apply 24 V between
tween and .
2) Disconnect connectors PM5 and R02.
Possible causes
and standard value ness Resistance Max. 1 Ω
in normal state 2 R02 (female)
Wiring harness between SF1 (female) and
R02 (female)
and chassis ground
2) Disconnect connectors BRC3B and PM3.
Grounding fault in wiring Min. 1 M Ω
3 male) and R02 (female) , R02 (female)
harness
and chassis ground
Wiring harness between SF1 (fe- tween SF1 (female)
Min. 1 M Ω
and chassis ground
4 Payload meter defective
Between PM6 When shift lever is N Voltage 20 – 30 V
and PM5 When shift lever is not N Voltage Max. 1.5 V
HD465-7, HD605-7 20-819

➀
20-820 HD465-7, HD605-7

➀
LC-7 DISPLAYED LOGIC IS ABNORMAL

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go off.
Action code Error code Controller code Displayed logic is abnormal

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer
Trouble
Not set Not set Not set does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go
off.
• When loaded dump truck starts traveling, "0" is kept displayed.
Contents of trouble • After loaded dump truck start traveling, display of odometer does not increase.
• When travel speed exceeds limit speed, "SP:SP" does not go off.
• When loaded dump truck starts traveling, "0" is kept displayed.
Problem that
• After loaded dump truck start traveling, display of odometer does not increase.
appears on machine
• When travel speed exceeds limit speed, "SP:SP" does not go off.
• If the pay load is displayed during loading but "0" is displayed after the dump truck starts traveling until
it dumps the load, the travel speed signal is not sensed.
Related information
• If error codes "DLT3KA" and "DLT3LC" related to transmission controller or error codes "DLT3KA" and
"dLT3LC" related to retarder controller are displayed, perform troubleshooting for them first.

2) Disconnect connectors PM5 and R02.
ness
1 Wiring harness between PM5 (female) and
Possible causes CN5 (female)
contact)
and standard value Wiring harness between PM5 (female) and
CN5 (female)
2 Payload meter defective 3) Connect T-adapter.
HD465-7, HD605-7 20-821

➀
d) Integrated pay load is not displayed.

Trouble
Not set Not set Not set d) Integrated pay load is not displayed.
Contents of trouble • Integrated pay load is not displayed.
Problem that
• Integrated pay load is not displayed.
appears on machine
• To display the integrated pay load, the following condition must be satisfied during the time from the
start to the end of dumping.
When the load was dumped previous time, it was reduced to below 1/5 of the rated pay load within
5 minutes after the dump lever was changed from "LOWER" to "FLOAT".
Related information
When the load was dumped previous time, "b-fl" was not displayed for 5 seconds just after the
dump lever was changed from "LOWER" to "FLOAT".
The load to be dumped this time is above 1/2 of the rated pay load.
• If the payload meter displays "b-fl", perform troubleshooting of LC-8.

and standard value
in normal state 1 If the payload meter displays "b-FL", perform troubleshooting of LC-8.
20-822 HD465-7, HD605-7

➀
e) Displayed and saved pay load is not correct.

Trouble
Not set Not set Not set e) Displayed and saved pay load is not correct.
Contents of trouble • Displayed and saved pay load is not correct.
Problem that
• Displayed and saved pay load is not correct.
appears on machine
• The error of the payload meter is ± 5%.
• The possible causes of display of wrong displayed and saved values are as follows
Defective setting of model selection switch of payload meter
Defective adjustment of suspension
Negligence of calibration of payload meter
Related information <Precautions>
i) If the load is dumped while the displayed pay load is changing because of pitching of the truck body,
the saved value may become inaccurate. Accordingly, dump after the displayed value is fixed.
ii) The pay load displayed in the loading place (just after loading) may be a little (1 - 5 t) less than that
displayed in the dumping place.
★ For details, see Operation Manual, 3. For higher accuracy.

LC display: "CO: X. X"
HD465-7 HD605-7
1 Wrong model setting
X. X
0. 7 0. A
display
i) When truck is empty
Empty, Flat place
★ See STRUCTURE AND OPERATION, Service Check Mode, (b)
Display of data for calculation of pay load.
Pressure difference between both sides
Possible causes 0.98 MPa {10 kg/cm2}
(Front)
and standard value
in normal state Pressure difference between both sides (Rear) 1.47 MPa {15 kg/cm2}
Improper suspension gas • If the pressure difference exceeds the above range, adjust the sus-
2
pressure pension gas, referring to "Testing and adjusting suspension cylin-
der".
ii) When truck is loaded
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
iii)When truck turns on slope
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
3 Improper calibration • Perform calibration according to the operation manual.
HD465-7, HD605-7 20-823

➀
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL"

(BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION
WHILE TRUCK IS NOT DUMPING)
Action code Error code Controller code Payload meter keeps displaying "b:FL"
Trouble (Body "FLOAT" signal system: Dump lever is not in "FLOAT" po-
Not set Not set Not set sition while truck is not dumping)
• Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
Contents of trouble
position while truck is not dumping)
Problem that • Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
appears on machine position while truck is not dumping)
• Check that error codes "DK52KX", "DK53L8", and "DK24KX" (failure in dump lever system) related to
Related information
retarder controller are not displayed. If any of them is displayed, perform troubleshooting for it.

Disconnection in wiring har- 2) Disconnect connectors PM6 and BRC1.
1
BRC1 (female)
2) Disconnect connectors PM6 and BRC1.
harness
Min. 1 M Ω
male) and BRC1 (female) , BRC1 (female)
and chassis ground
and standard value 2) Disconnect connector BRC1.
in normal state 3) Insert T-adapter.
3 Retarder controller defective 5) Turn the starting switch ON.
Between BRC1 Dump lever is in "FLOAT". Voltage 20 – 30 V

and chassis Dump lever is out of
ground Voltage Max. 1 V
"FLOAT".
4 Payload meter defective 5) Turn the starting switch ON.
Between PM6 Dump lever is in "FLOAT". Voltage 20 – 30 V
and chassis Dump lever is out of
ground Voltage Max. 1 V
"FLOAT".
20-824 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-825

➀
TROUBLESHOOTING LC-9, LC-10
LC-9 PAYLOAD METER DISPLAYS "F:09"

(LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)

Payload meter displays "F:09"
Payload meter Trouble
Not set Not set (Lowering of internal backup battery voltage)
displays "F:09"
Contents of trouble • Payload meter displays "F:09" (Lowering of internal backup battery voltage)
Problem that
• Payload meter displays "F:09" (Lowering of internal backup battery voltage)
appears on machine

and standard value Lowering of internal backup
in normal state 1 Replace the internal backup battery according to the operation manual.
battery voltage
LC-10 PAYLOAD METER DISPLAYS " :FULL"

(DATA SAVING MEMORY IS FULL)

Payload meter Payload meter displays " :FULL"
Trouble
Not set displays Not set (Data saving memory is full)
" :FULL"
Contents of trouble • Payload meter displays " :FULL". (Data saving memory is full.)
Problem that
• Payload meter displays " :FULL". (Data saving memory is full.)
appears on machine

Cycle data saving memory
• Download the data to a personal computer and clear the memory to
1 full
"0" (zero ) according to the operation manual.
★ "L. FULL" is displayed
Engine ON/OFF data saving
2 memory full
Possible causes "0" (zero ) according to the operation manual.
★ "E. FULL" is displayed
and standard value
in normal state Failure and warning data
3 saving memory full
"0" (zero ) according to the operation manual.
★ "F. FULL" is displayed
Integrated pay load and total
number of cycles data sav- • Download the data to a personal computer and clear the memory to
4
ing memory full "0" (zero ) according to the operation manual.
★ "F. FULL" is displayed
20-826 HD465-7, HD605-7

➀
LC-11 PAYLOAD METER DISPLAYS "F-20"

: FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND
CLINOMETER SYSTEM
Action code Error code Controller code LC-11 Payload meter displays "F-20"
Payload meter Trouble : Failure in power source of suspension pressure sensor and cli-
Not set Not set nometer system
displays "F-20"
Contents of trouble • The sensor power source output is below 15 V while the source voltage is above 20 V.
Action of controller • All the external pilot lamps flash.
Problem that • Pay load is not displayed correctly.
appears on machine • Operation data is not saved correctly.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, SURR, and PM3.
Min. 1 M Ω
male) and SUFL (female) , SUFL (female)
and chassis ground
Min. 1 M Ω
male) and SUFR (female) , SUFR (female)
and chassis ground
harness
Min. 1 M Ω
male) and SURL (female) , SURL (female)
and chassis ground
Min. 1 M Ω
male) and SURR (female) , SURR (female)
and chassis ground
Possible causes
and standard value Min. 1 M Ω
male) and PM3 (female) , PM3 (female)
in normal state
and chassis ground
2) Replace the sensor.
When front left suspension pressure sensor is Front left sensor is de-
replaced, the error is corrected. fective.
When front left suspension pressure sensor is Front left sensor is
replaced, the error is not corrected. normal.
When front right suspension pressure sensor Front right sensor is
is replaced, the error is corrected. defective.
2 When front right suspension pressure sensor Front right sensor is
defective
is replaced, the error is not corrected. normal.
When rear left suspension pressure sensor is Rear left sensor is de-
When rear left suspension pressure sensor is Rear left sensor is nor-
replaced, the error is not corrected. mal.
When rear right suspension pressure sensor is Rear right sensor is
replaced, the error is corrected. defective.
When Rear right suspension pressure sensor Rear right sensor is
HD465-7, HD605-7 20-827

➀

3 Clinometer sensor defective When the clinometer is replaced, the error is Clinometer is defec-
Possible causes corrected. tive.
and standard value When the clinometer is replaced, the error is
in normal state Clinometer is normal.
not corrected.
4 Payload meter defective 3) Connect T-adapter (only payload meter side).
Between PM6 (male) and Voltage 18 ± 3 V
20-828 HD465-7, HD605-7

➀
LC-12 PAYLOAD METER DISPLAYS "F-21" – "F-24"

: DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL
SYSTEM
Payload meter displays "F-21" – "F-24"
Payload meter Trouble : Disconnection or grounding fault in suspension sensor signal
Not set displays Not set system
"F-21" – "F-24"
Contents of trouble • Input signal of suspension pressure sensor is below 1 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR.
SUFL (female)
SUFR (female)
SURL (female)
SURR (female)
Disconnection in wiring har- SUFL (female) Resistance Max. 1 Ω
ness
1 Wiring harness between PM6 (female) and
SUFR (female)
contact)
SURL (female)
SURR (female)
SUFL (female)
Possible causes
and standard value Resistance Max. 1 Ω
in normal state SUFR (female)
SURL (female)
SURR (female)
2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Min. 1 M Ω
male) and SUFL (female) , SUFL (female)
and chassis ground
2 male) and SUFR (female) , SUFR (female)
harness
and chassis ground
Min. 1 M Ω
male) and SURL (female) , SURL (female)
and chassis ground
Min. 1 M Ω
male) and SURR (female) , SURR (female)
and chassis ground
HD465-7, HD605-7 20-829

➀

defective
Possible causes When rear left suspension pressure sensor is Rear left sensor is nor-
and standard value replaced, the error is not corrected. mal.
in normal state
2) Disconnect connectors PM5 and PM6.
4 Payload meter defective Between PM6 and Voltage 18 ± 3 V
Between PM6 and Voltage 1–5V
20-830 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-831

➀
LC-13 PAYLOAD METER DISPLAYS "F-25" – "F-28"

: SHORT CIRCUIT WITH POWER SOURCE IN SUSPENSION SENSOR SIGNAL
SYSTEM

Payload meter displays "F-25" – "F-28"
Payload meter Trouble : Short circuit with power source in suspension sensor signal sys-
Not set displays Not set tem
"F-25" – "F-28"
Contents of trouble • The suspension pressure input signal is above 5 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Voltage between PM6
Wiring harness between PM6 (fe- (female) , SUFL (fe-
Max. 1 V
male) and SUFL (female) male) and chassis
ground
Voltage between PM6
Short circuit with power Wiring harness between PM6 (fe- (female) , SUFR
1 Max. 1 V
source in wiring harness male) and SUFR (female) (female) and chas-
sis ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) , SURL (fe-
Max. 1 V
male) and SURL (female) male) and chassis
ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) , SURR
Max. 1 V
Possible causes male) and SURR (female) (female) and chas-
and standard value sis ground
defective
20-832 HD465-7, HD605-7

➀

and standard value
in normal state 3 Payload meter defective Between PM6 and Voltage 18 ± 3 V
HD465-7, HD605-7 20-833

➀
LC-14 PAYLOAD METER DISPLAYS "F-CAL"

(NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)

Payload meter Payload meter displays "F-CAL"
Trouble
Not set displays Not set (Negligence of calibration or internal damage of payload meter)
"F-CAL"
Contents of trouble • Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
Problem that
• Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
appears on machine

Possible causes Negligence of calibration or
and standard value internal damage of payload
in normal state 1 • Repair according to the operation manual.
meter
★ "F-CAL" is displayed.
20-834 HD465-7, HD605-7

➀
LC-15 PAYLOAD METER DISPLAYS "F:43" – "F:45"

(SHORT CIRCUIT WITH POWER SOURCE IN EXTERNAL PILOT LAMP RELAY
SYSTEM)
Action code Error code Controller code Payload meter displays "F:43" – "F:45"
Trouble
Not set Not set Not set (Short circuit with power source in external pilot lamp relay system)
Contents of trouble • There is short circuit with power source in external pilot lamp relay system.
Problem that • There is short circuit with power source in external pilot lamp relay system.
appears on machine • Payload meter displays "F:43" – "F:45".

No
Payload meter lamp relays placed with normal ones respec- Relays (R43), (R44),
Yes
(R43), (R44), and (R45) de- tively, is failure repaired? and (R45) are defective
fective 1) Turn the starting switch OFF.
★ When "F:43" is displayed, 2) Disconnect connectors R43, R44, and R45.
1 R43 is defective. 3) Check the relays.
★ When "F:44" is displayed,
R44 is defective. Between R43, R44, and R45 and Resistance 200 – 400 Ω
★ When "F:45" is displayed, 1) Turn the starting switch OFF.
R45 is defective. 2) Disconnect connectors R43, R44, and R45.
Apply 24 V between
and R45 and . Do not apply 24 V be-
tween and .
and standard value
2) Disconnect connectors PM5, R40, R43, R44, and R45.
source in wiring harness Voltage between PM5
★ When "F:43" is displayed, Wiring harness between PM5 (fe- (female) , R43 (fe-
Max. 1 V
R43 system is short-cir- male) and R43 (female) male) and chassis
cuited. ground
2 ★ When "F:44" is displayed, Voltage between PM5
R44 system is short-cir- Wiring harness between PM5 (fe- (female) , R44 (fe-
cuited. Max. 1 V
★ When "F:45" is displayed, ground
R45 system is short-cir-
Voltage between PM5
cuited.
Wiring harness between PM5 (fe- (female) , R45 (fe-
Max. 1 V
ground
2) Disconnect connectors R40, R43, R44, and R45.
3 Voltage between PM5
Max. 1 V
ground
HD465-7, HD605-7 20-835

➀

Voltage between PM5
Max. 1 V
Short circuit with power ground
3
Max. 1 V
Possible causes ground
and standard value
Payload meter defective 1) Turn the starting switch OFF.
in normal state
★ When "F:43" is displayed, 2) Disconnect connector PM5.
PM5 system is defec- 3) Insert T-adapter.
tive. 4) Connect the connector.
★ When "F:44" is displayed, 5) Turn the starting switch ON.
4
PM5 system is defec-
Between PM 5 and Voltage 20 – 30 V
tive.
★ When "F:45" is displayed, Between PM 5 and Voltage 20 – 30 V
PM5 system is defec-
tive. Between PM 5 and Voltage 20 – 30 V
20-836 HD465-7, HD605-7

➀
LC-16 PAYLOAD METER DISPLAYS "L-bad"

(CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)
Action code Error code Controller code Payload meter displays "L-bad"
Trouble
Not set Not set Not set (Cycle data were saved while truck body was pitching)
Contents of trouble • Since truck pitches during dumping, the pay load in the cycle data is not correct.
Problem that
• Since truck pitches during dumping, the pay load in the cycle data is not correct.
appears on machine
• The pay load must be calculated accurately and saved as a cycle data when the truck dumps. If the
truck pitches when it dumps, the calculation accuracy is lowered. Pitching of the truck during dumping
is notified to the operator by "L-bad". Accordingly, wait for 5 seconds after the truck stops, and then
Related information start dumping.
• If "L-bad" is displayed during dumping, it is maintained until the empty truck starts traveling.
• If "L-bad" is always displayed and the pay load in the cycle data is abnormal, perform the following
troubleshooting.

2) Disconnect connectors PM5, PM6, SUFL, SUFR, SURL, and SURR.
SUFR (female)
1 SUFL (female)
SUFR (female)
SURL (female)
SURR (female)
Possible causes 2) Replace the sensor.
and standard value 3) Turn the starting switch ON.
in normal state When front left suspension pressure sensor is Front left sensor is de-
defective
HD465-7, HD605-7 20-837

➀

and standard value
in normal state 3 Payload meter defective Between PM6 and Voltage 18 ± 3 V
20-838 HD465-7, HD605-7

➀
LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING
LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M
AFTER IT IS LOADED
Action code Error code Controller code External pilot lamp indicates forecast while truck is not being
Trouble loaded or clock is displayed while truck travels for 160 m after it
Not set Not set Not set is loaded
• External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
Contents of trouble
travels for 160 m after it is loaded
Problem that • External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
appears on machine travels for 160 m after it is loaded

and standard value
in normal state 1 Improper calibration • Perform calibration according to the operation manual.
HD465-7, HD605-7 20-839

➀

: GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL
SYSTEM
Action code Error code Controller code Payload meter displays "F-31"
Payload meter Trouble : Grounding fault or disconnection in clinometer sensor signal
Not set Not set system
displays "F-31"
Contents of trouble • The signal circuit voltage of the clinometer sensor is below 1.6 V.
• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

1 PM3 (female)
PM3 (female)
PM3 (female)
harness
Possible causes Wiring harness between PM6 (fe- tween PM6 (female)
Min. 1 M Ω
and standard value male) and PM3 (female) , PM3 (female)
3 Clinometer sensor defective When the clinometer is replaced, error is cor- Clinometer is defec-
rected. tive.
When the clinometer is replaced, error is not
Clinometer is normal.
corrected.
Between PM6 and Voltage 18 ± 3 V
Between PM6 and Voltage 1.6 – 3.6 V
20-840 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-841

➀

: SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL
SYSTEM

Payload meter Trouble Payload meter displays "F-32"
Not set Not set
displays "F-32"
Contents of trouble • The signal circuit voltage of the clinometer sensor is above 3.6 V.
• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

1
Wiring harness between PM6 (fe- (female) , PM3 (fe-
Max. 1 V
male) and PM3 (female) male) and chassis
ground
Possible causes 2) Disconnect connector PM3.
in normal state 2 Clinometer sensor defective 4) Connect the connector.
Between PM3 and Voltage 18 ± 3 V
Between PM3 and Voltage 1.6 – 3.6 V
3 Payload meter defective 4) Connect the connectors.
Between PM6 and PM5 Voltage 18 ± 3 V
Between PM6 and PM5 Voltage 1.6 – 3.6 V
20-842 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-843

➀
LC-20 PAYLOAD METER DISPLAYS "F:18"

(DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)
Action code Error code Controller code Payload meter displays "F:18"
Trouble
Not set Not set Not set (Disconnection in charge level signal system)
Contents of trouble • There is disconnection in the charge level signal system.
Problem that • There is disconnection in the charge level signal system.
appears on machine • Payload meter displays "F:18".
• If error code "AB00MA" (Malfunction of alternator) related to transmission controller is displayed, per-
Related information
form troubleshooting for it first.

ness 4) Connect the connector.
1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) and alternator terminal R and chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 and chassis ground Voltage Min. 5 V
20-844 HD465-7, HD605-7

➀
TROUBLESHOOTING FOR
MONITOR SYSTEM
(MON MODE)
Electrical system diagram related to monitor .............................................................................................. 20-904

Information in troubleshooting table........................................................................................................ 20-905
Trouble code table .................................................................................................................................. 20-906
[B@C7NS] Rear brake oil: overheating (NS) ........................................................................................ 20-907
[B@CENS] Torque converter: overheating (NS) ................................................................................... 20-907
[DAF0KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-908
[DAF9KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-911
[DAFSKQ] Monitor panel: disagreement of model selection signals (KQ) ........................................... 20-912
[DAQSKR] S-NET communication defective
(between transmission controller and machine monitor) (KR)............................................ 20-913
[DASRKR] CAN communication • Communication defective: abnormality in objective component (KR) .. 20-916
[DB1SKR] S-NET communication defective (between retarder controller and machine monitor) (KR)..... 20-918
[DV00KB] Short circuit in alarm buzzer output • short circuit (KB) ...................................................... 20-921
MON- 1 When starting switch is turned ON, machine monitor does not display any item ............... 20-922
MON- 2 When starting switch is turned OFF and machine monitor does not operate normally ...... 20-923
MON- 3 Alarm buzzer defective ....................................................................................................... 20-925
a) Alarm buzzer does not sound ....................................................................................... 20-925
b) Alarm buzzer does not stop sounding........................................................................... 20-926
MON- 4 Items displayed by gauges, caution lamps, and character display of machine monitor
are abnormal ...................................................................................................................... 20-927
a) Items displayed by gauges are different from machine condition ................................. 20-927
b) Items displayed by caution lamps are different from machine condition ....................... 20-928
c) Character display does not display any item or it displays abnormally ......................... 20-928
MON- 5 Operation of machine monitor cannot be checked normally .............................................. 20-929
MON- 6 Display of character display cannot be selected normally.................................................. 20-930
a) Machine monitor mode select switch 1 system is abnormal ......................................... 20-930
b) Machine monitor mode select switch 2 system is abnormal ......................................... 20-932
MON- 7 Power mode select function does not work normally ......................................................... 20-934
MON- 8 Seat belt caution lamp does not operate normally ............................................................. 20-935
a) Lamp lights up while seat belt is fastened..................................................................... 20-935
b) Lamp does not light up while seat belt is unfastened.................................................... 20-936
MON- 9 Turn signals and hazard lamp do not operate normally...................................................... 20-937
a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp
does not flash................................................................................................................ 20-937
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps
do not flash but light up ................................................................................................. 20-938
c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash
(When hazard lamp switch is operated, however, turn signal lamps flash normally) ......... 20-939
d) When hazard lamp switch is turned ON, any turn signal lamp does not flash
(When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-940
e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing
(When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-942
f) Turn signal pilot lamps do not flash normally
(Turn signal lamps flash normally, however) ................................................................. 20-943
HD465-7, HD605-7 20-901

➁
MON-10 Night lighting is abnormal ................................................................................................... 20-945
a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp,
and head lamp does not light up. .................................................................................. 20-945
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up ..... 20-946
c) When lamp switch is OFF, small lamp and night lamp light up ..................................... 20-947
d) When dimmer switch is operated, brightness of night lighting does not change........... 20-948
e) Head lamp "Hi" beam does not light up ........................................................................ 20-949
f) Head lamp "Lo" beam does not light up........................................................................ 20-950
g) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-951
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-952
MON-11 Power window does not operate normally.......................................................................... 20-954
a) Operating left side does not .......................................................................................... 20-954
b) Operating right side does not ........................................................................................ 20-955
MON-12 Defective air conditioner ..................................................................................................... 20-957
a) Air conditioner does not operate ................................................................................... 20-957
b) Air does not come out or air flow cannot be adjusted ................................................... 20-958
c) Air is not cooled or temperature cannot be adjusted (Electric system) ......................... 20-960
d) Recirculated air and fresh air cannot be selected ......................................................... 20-962
e) Air outlets cannot be selected ....................................................................................... 20-963
f) Air is not cooled (Mechanical system)........................................................................... 20-965
g) Air is not heated (Defective hot water circuit)................................................................ 20-966
h) Abnormal sound comes out .......................................................................................... 20-966
i) Water leaks ................................................................................................................... 20-967
★ For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM
Mode).
20-902 HD465-7, HD605-7

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

★ For details of this page, see page 90-21.
20-904 HD465-7, HD605-7

➁


panel panel panel
Problem that
appears on machine

1
• Disconnection
• Short circuit
3
side.
side.
5
side.
HD465-7, HD605-7 20-905

➀

TROUBLE CODE TABLE




MW Sliding
NS Overheat
20-906 HD465-7, HD605-7

➀
TROUBLESHOOTING [B@C7NS], [B@CENS]
[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS)
Action code Error code Controller code Rear brake oil: Overheating (NS)
Trouble
E02 B@C7NS MON (Brake cooling oil overheating)
Contents of trouble • Brake cooling oil is overheating
Problem that
• If the machine is used without repairing, the rear brake may be broken.
appears on machine
Related information • This error code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of brake cool-
1
and standard value ing oil
in normal state
• If the brake cooling oil is not overheating, the machine monitor is de-
fective.
[B@CENS] TORQUE CONVERTER: OVERHEATING (NS)

Trouble Torque converter: Overheating (NS)
E02 B@CENS MON
Contents of trouble • Torque converter is overheating
Problem that
• If the machine is used without repairing, the torque may be broken.
appears on machine
Related information • This error code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of torque con-
1
and standard value verter
in normal state
• If the torque converter is not overheating, the machine monitor is de-
fective.
HD465-7, HD605-7 20-907

➀
TROUBLESHOOTING [DAF0KM]
[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)

Action code Error code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF0KM MON (Disagreement of optional settings)
• The optional settings of the rotary switch and dip switch on the rear side of the machine monitor do not
Contents of trouble
agree with the signals of the optional setting connector.
• The controller maintains the abnormal state until the starting switch is turned OFF.
• The controller does not recognize the functions (optional), the settings of which do not agree the sig-
nals.
• The controller does not record this failure in the failure history.
Problem that
• Some functions (optional) do not work.
appears on machine
• Connections of wiring harnesses OP1–OP7 depend on the specification. For details, see "Adjustment
of machine monitor".
• This failure can be checked with SW1–3 (Model code: 30800), SW5–1, 5–2 (Model code: 30900),
Related information SW5–3, 5–4 (Model code: 30901), SW6–1, 6–2 (Model code: 30902), SW6–3, and 6–4 (Model code:
30903) on the rear side of the machine monitor.
• This failure can be checked with optional selection connectors OP1, 2 (Model code: 31000), OP3, 4
(Model code: 31001), and OP5, 6 (Model code: 31002).

2) Disconnect connector DPC3A.
When connected tween DPC3A (fe-
Max. 1 Ω
Wiring harness (CLOSED) male) and chassis
between DPC3A ground
(female) and Resistance value be-
OP1 (female) When discon-
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
ground
Max. 1 Ω
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
ground
and standard value Grounding fault in wiring Max. 1 Ω
in normal state 1 Wiring harness (CLOSED) male) and chassis
harness
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
ground
Max. 1 Ω
tween DPC3A (fe-
nected Min. 1 M Ω
male) ( and chassis
(OPENED)
ground
Max. 1 Ω
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
ground
20-908 HD465-7, HD605-7

➀

Max. 1 Ω
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
Grounding fault in wiring ground
1
Max. 1 Ω
tween DPC3A (fe-
nected Min. 1 M Ω
male) and chassis
(OPENED)
ground
Resistance value be- When connected
tween DPC3A (fe- (CLOSED)
male) and chassis When disconnected
Possible causes (OPENED)
and standard value Resistance value be- When connected Resistance Max. 1 Ω
in normal state tween DPC3A (fe- (CLOSED)
(OPENED)
Resistance value be- When connected Resistance Max. 1 Ω
(OPENED)
2 Machine monitor defective Resistance value be- When connected
(OPENED)
(OPENED)
(OPENED)
Resistance value be- When connected
(OPENED)
HD465-7, HD605-7 20-909

➀
20-910 HD465-7, HD605-7

➀
[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)
Action code Error code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF9KM MON (Wrong connection of connector)
Contents of trouble • The check signal of the connector does not agree with the internal setting of the machine monitor.
• The controller does not record this failure in the failure history.
• The machine monitor mode select switch does not work.
Problem that
• The optional functions do not work.
appears on machine
• The head lamp HIGH pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.

The connector check signal connectors are connected normally.
1 ★ Connector check signal connectors: DPC3A (OPEN), DPC2A
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector DPC2A.
2
Wiring harness between fuse terminal BT4
and DPC2A (female)
and standard value 2) Disconnect connector DPC3A.
in normal state Grounding fault in wiring 3) Connect T-adapter.
3 harness Wiring harness between DPC3A (female)
(Grounding fault of terminal) and chassis ground
★ This must not occur basically, since the wiring harness is not con-
nected.
4 Machine monitor defective 3) Connect T-adapter.
Resistance value between DPC2A (female)
and chassis ground
HD465-7, HD605-7 20-911

➀
TROUBLESHOOTING [DAFSKQ]
[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)

Trouble Monitor panel: Disagreement of model selection signals (KQ)
E03 DAFSKQ MON
• Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or the rotary switch of the transmission controller is not set normally.
• The controller controls the truck as HD465-7.
Problem that • None of the meters and gauges display.
appears on machine • Some panel switches and lamps do not work.
Related information • If another error code "DAQAKQ" is displayed, perform troubleshooting for it.

Communication circuit de-
1 Perform troubleshooting for "DAQSKR".
fective
Possible causes ★ If the failure is not repaired by replacing the machine monitor, the
and standard value machine monitor is defective.
in normal state 2 Machine monitor defective
★ When replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
Transmission controller de- ★ If the failure is not repaired by replacing the machine monitor, the
3
fective transmission controller is defective.
20-912 HD465-7, HD605-7

➀
TROUBLESHOOTING [DAQSKR]
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CON-

TROLLER AND MACHINE MONITOR) (KR)
Action code Error code Controller code S-NET communication defective (KR)
Trouble
E03 DAQSKR MON (Between transmission controller and machine monitor)
Contents of trouble • Communication (S-NET) information cannot be obtained from the transmission controller.
Action of controller • The controller maintains the condition at the time when the failure occurs.
Problem that • The meters, gauges, caution lamps, and special functions that obtain information from the transmis-
appears on machine sion controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 Ω
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 Ω
Between each couple of JCD (male) terminals Resistance Max. 1 Ω
Between each couple of JCE (male) terminals Resistance Max. 1 Ω
Between each couple of JCF (male) terminals Resistance Max. 1 Ω
Between each couple of JCG (male) terminals Resistance Max. 1 Ω
2) Disconnect connectors DPC4, ATC4, and BRC4.
Wiring harness between DPC4 (female)
and ATC4 (female)
Disconnection in wiring har- and ATC4 (female) Resistance Max. 1 Ω
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) Resistance Max. 1 Ω
contact) and ATC4 (female)
and ATC4 (female)
and standard value
in normal state ★ If another controller also has an error in S-NET communication, per-
form troubleshooting from the wiring harness.
★ Disconnect the connectors to which the S-NET signals of all the con-
trollers connected to S-NET are allotted.
Between DPC4 (female) , and chassis
Grounding fault in wiring Resistance Min. 1 M Ω
3 ground
harness
★ If another controller also has an error in S-NET communication, per-
Short circuit with power Between DPC4 (female) , and chassis
4 Voltage Max. 1 V
source in wiring harness ground
HD465-7, HD605-7 20-913

➀

and standard value Transmission controller de- Between ATC4 and Voltage 6–9V
in normal state 5
fective Between ATC4 and Voltage 6–9V
★ If any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the transmission
controller and check that the transmission controller is outputting the
normal voltage.
20-914 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-915

➁
TROUBLESHOOTING [DASRKR]
[DASRKR] CAN COMMUNICATION • COMMUNICATION DEFECTIVE: ABNORMALITY

IN OBJECTIVE COMPONENT (KR)
Action code Error code Controller code CAN communication • Communication defective: Abnormality in
Trouble objective component (KR)
E03 DASRKR MON (Between engine controller and machine monitor)
Contents of trouble • Communication (CAN) information cannot be obtained from the engine controller.
Problem that • The meters, gauges, caution lamps, and special functions that obtain information from the engine con-
appears on machine troller do not operate or display.
Related information

2) Disconnect connector JC14.
1 Junction connector defective 3) Connect T-adapter.
Between JC14 (male) and Resistance Max. 1 Ω
Between JC14 (male) and Resistance Max. 1 Ω
2) Disconnect connectors DPC4 and ECMB.
and DPC4 (female)
2 Wiring harness defective
★ Check that terminal resistors CAN and CAN2 are connected. The
resistance value of each terminal resistor is 120 Ω.
★ Check that a personal computer or a controller is not connected to
CAN1.
Possible causes ★ If VHMS is connected, disconnect it.
and standard value
2) Replace the engine controller.
3 Engine controller defective Engine controller is
When the engine controller is re- No
normal.
placed, does communication be-
come normal? Engine controller is
Yes
defective.
2) Replace the machine monitor.
Machine monitor is
When the machine monitor is re- No
4 Machine monitor defective normal.
placed, does communication be-
come normal? Machine monitor is de-
Yes
fective
★ When replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
20-916 HD465-7, HD605-7

➀
TROUBLESHOOTING [DASRKR]
HD465-7, HD605-7 20-917

➀
TROUBLESHOOTING [DB1SKR]
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROL-

LER AND MACHINE MONITOR) (KR)
Action code Error code Controller code S-NET communication defective (KR)
Trouble
E03 DB1SKR MON (Between retarder controller and machine monitor)
Contents of trouble • Communication (S-NET) information cannot be obtained from the retarder controller.
Problem that • The meters, gauges, caution lamps, and special functions that obtain information from the retarder
appears on machine controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 Ω
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 Ω
Between each couple of JCD (male) terminals Resistance Max. 1 Ω
Between each couple of JCE (male) terminals Resistance Max. 1 Ω
Between each couple of JCF (male) terminals Resistance Max. 1 Ω
Between each couple of JCG (male) terminals Resistance Max. 1 Ω
and BRC4 (female)
Disconnection in wiring har- and BRC4 (female) Resistance Max. 1 Ω
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) Resistance Max. 1 Ω
contact) and BRC4 (female)
and BRC4 (female)
and standard value
in normal state ★ If another controller also has an error in S-NET communication, per-
Between DPC4 (female) , and chassis
Grounding fault in wiring Resistance Min. 1 M Ω
3 ground
harness
Short circuit with power Between DPC4 (female) , and chassis
4 Voltage Max. 1 V
source in wiring harness ground
20-918 HD465-7, HD605-7

➀

and standard value
in normal state 5 Retarder controller defective Between BRC4 and Voltage 6–9V
Between BRC4 and Voltage 6–9V
★ If any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the retarder control-
ler and check that the retarder controller is outputting the normal
voltage.
HD465-7, HD605-7 20-919

➀
20-920 HD465-7, HD605-7

➁
TROUBLESHOOTING [DV00KB]
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT • SHORT CIRCUIT (KB)

Trouble Short circuit in alarm buzzer output • Short circuit (KB)
E01 DV00KB MON
Contents of trouble • There is short circuit with the power source in the output circuit of the alarm buzzer.
• The controller turns the output circuit of the alarm buzzer OFF.
Problem that
• The alarm buzzer does not sound.
appears on machine

2) Disconnect connectors DPC1 and BZ2.
1
Wiring harness between DPC1 DPC1 (female) ,
Max. 1 V
(female) and BZ2 (female) BZ2 (female) and
Possible causes
chassis ground
and standard value
2) Disconnect connector BZ2 and remove the buzzer.
3) Connect +24 V to BZ2 (male) and connect GND to BZ2 (male) .
2 Alarm buzzer defective The alarm buzzer sounds. Alarm buzzer is normal.
The alarm buzzer does not sound. Alarm buzzer is defective.
★ Check the alarm buzzer unit.
• If the results of 1) and 2) above are normal, the machine monitor is
defective.
HD465-7, HD605-7 20-921

➀
TROUBLESHOOTING MON-1
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT
DISPLAY ANY ITEM
Action code Error code Controller code When starting switch is turned ON, machine monitor does not
Trouble
Not set Not set MON display any item
Contents of trouble • When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
Problem that
• When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
appears on machine
Related information • Before performing troubleshooting, check that fuses BT2 and BT2 and fusible link FUA are not
broken.

Wiring harness between battery Voltage between BT2
20 – 30 V
relay B and fuse BT2 and chassis ground
Voltage between
Disconnection in wiring har- Wiring harness between fuse BT2
DPC1 , and 20 – 30 V
ness and DPC1 (female) and
1 chassis ground
Possible causes contact) 1) Turn the starting switch OFF.
and standard value 2) Disconnect connectors DPC4 and BRC4.
Wiring harness between DPC1 , and
chassis ground
2 Machine monitor defective 3) Insert T-adapter.
Between DPC1 , and , Voltage 20 – 30 V
20-922 HD465-7, HD605-7

➀
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES
NOT OPERATE NORMALLY
Action code Error code Controller code When starting switch is turned OFF and machine monitor does
Trouble
Not set Not set MON not operate normally
• When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
service meter and odometer are not displayed.
Contents of trouble
• When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
• When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
Problem that service meter and odometer are not displayed.
appears on machine • When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
• Before performing troubleshooting, check that fuses BT2 and BT2 and fusible link FUA are not
Related information
broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring har-
ness.)

When the starting switch is turned
Main power source (SW power
ON, the machine monitor operates
source) is normal.
normally.
Main power source (SW Even if the starting switch is turned
1 Main power source (SW power
power source) defective ON, the machine monitor does not
source) is defective.
operate normally.
★ If the main power source (SW power source) is defective, perform
troubleshooting of MON-1.
Disconnection in wiring har- Wiring harness between J01 (fe- Voltage between BT2
20 – 30 V
ness male) (Y) and fuse BT2 and chassis ground
Possible causes 2
(Disconnection or defective Voltage between
and standard value Wiring harness between fuse BT2
contact) DPC1 , and 20 – 30 V
in normal state and DPC1 (female) ,
chassis ground
Hazard lamp switch, related
3 wiring harness, or related re- ★ Referring to MON-9 d), perform troubleshooting.
lay defective
Machine monitor mode se-
4 lect switch 1 or related wiring ★ Referring to MON-6, perform troubleshooting.
harness defective
5 Machine monitor defective 3) Insert T-adapter.
★ Keep the starting switch OFF.
Between DPC1 , and , Voltage 20 – 30 V
HD465-7, HD605-7 20-923

➀
20-924 HD465-7, HD605-7

➀
MON-3 ALARM BUZZER DEFECTIVE

a) Alarm buzzer does not sound
Action code Error code Controller code Alarm buzzer defective

Trouble
Not set Not set MON a) Alarm buzzer does not sound
• When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
• If error code "DV00KB" is displayed, perform troubleshooting for it.
Related information
• Before performing troubleshooting, check that the fuse is not broken and the voltage between B22 and
chassis ground is 20 – 30 V when the starting switch is ON.

2) Disconnect connectors BZ2 and battery BT4 terminal .
ness
1 Wiring harness between fuse BT4 and BZ2
(female)
contact)
Wiring harness between BZ2 (female) and
DPC (female)
2) Connect BZ2 to the chassis ground.
2 Alarm buzzer defective
Possible causes The alarm buzzer sounds. Alarm buzzer is normal.
and standard value The alarm buzzer does not sound. Alarm buzzer is defective.
in normal state
Under the condition for turning the Voltage between
Max. 1 V
3 Machine monitor defective alarm buzzer ON DPC1 and ,
20 – 30 V
alarm buzzer OFF DPC1 and ,
★ The condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
HD465-7, HD605-7 20-925

➀
b) Alarm buzzer does not stop sounding
Action code Error code Controller code Alarm buzzer defective

Trouble
Not set Not set MON b) Alarm buzzer does not stop sounding
• When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
Related information
• If error code "DV00KB" is displayed, perform troubleshooting for it.

2) Disconnect connectors BZ2 and battery BT4 terminal .
Short circuit in wiring har- Resistance value between wiring harness between fuse
1
ness BT4 and BZ2 (female) and wiring harness between Min. 1 M Ω
DPC1 (female) and BZ2 (female)
Wiring harness between BZ2 (female) and
DPC (female)
Possible causes
in normal state 2) Disconnect connector DPC1.
Max. 1 V
2 Machine monitor defective alarm buzzer ON DPC1 and ,
20 – 30 V
alarm buzzer OFF DPC1 and ,
★ The condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
20-926 HD465-7, HD605-7

➀
MON-4 ITEMS DISPLAYED BY GAUGES, CAUTION LAMPS, AND CHARACTER DIS-

PLAY OF MACHINE MONITOR ARE ABNORMAL
a) Items displayed by gauges are different from machine condition
Action code Error code Controller code Items displayed by gauges, caution lamps, and character display
Trouble of machine monitor are abnormal
Not set Not set MON a) Items displayed by gauges are different from machine condition
• The items displayed by the gauges, caution lamps, and character display of the machine monitor are
Contents of trouble
abnormal. (The items displayed by the gauges are different from the machine condition.)
Problem that • The items displayed by the gauges, caution lamps, and character display of the machine monitor are
appears on machine abnormal. (The items displayed by the gauges are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Sensor signal system
signal is monitored, the gauges display nor-
is normal.
Sensor signal system defec- mally.
1
tive If the inputting condition of the related sensor
Possible causes Sensor signal system
signal is monitored, the gauges do not display
and standard value is defective.
normally.
in normal state
★ If the sensor signal system is defective, perform troubleshooting for
each related signal system.
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the gauges display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the gauges do not display normally. fective.
HD465-7, HD605-7 20-927

➀
b) Items displayed by caution lamps are different from machine condition
of machine monitor are abnormal
Trouble
Not set Not set MON b) Items displayed by caution lamps are different from machine
condition
Contents of trouble
abnormal. (The items displayed by the caution lamps are different from the machine condition.)
appears on machine abnormal. (The items displayed by the caution lamps are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Switch or sensor sig-
signal is monitored, the gauges display nor-
nal system is normal.
mally.
Switch or sensor signal sys- If the inputting condition of the related sensor Switch or sensor sig-
1
tem defective signal is monitored, the gauges do not display nal system is defec-
Possible causes normally. tive.
and standard value
in normal state ★ If the switch or sensor signal system is defective, perform trouble-
shooting for each related signal system.
(See troubleshooting for the controllers to which the related sensor
signals are input.)
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the lamps display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the lamps do not display normally. fective.
c) Character display does not display any item or it displays abnormally
of machine monitor are abnormal
Trouble
Not set Not set MON c) Character display does not display any item or it displays abnor-
mally
Contents of trouble
abnormal. (The character display does not display any item or it displays abnormally.)
appears on machine abnormal. (The character display does not display any item or it displays abnormally.)

Possible causes If the machine monitor check switch is operat- Machine monitor is
and standard value ed, the character display displays normally. normal.
in normal state 1 Machine monitor defective
If the machine monitor check switch is operat-
Machine monitor is de-
ed, the character display does not display nor-
fective.
mally.
20-928 HD465-7, HD605-7

➀
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY

Trouble Operation of machine monitor cannot be checked normally
Not set Not set MON
• When the machine monitor check switch is operated, any of the lamps and gauges does not display.
Contents of trouble
Or, the lamps continue the operation while the machine monitor check switch is not operated.
Problem that • When the machine monitor check switch is operated, any of the lamps and gauges does not display.
appears on machine Or, the lamps continue the operation while the machine monitor check switch is not operated.

2) Disconnect connector CK1.
3) Check the switch
Machine monitor check
1 Between Operate (Press) the machine mon-
switch defective Resistance Max. 1 Ω
CK1 itor check switch.
(male) Do not operate (Release) the ma-
chine monitor check switch.
2) Disconnect connectors DPC2A, CK1, and fuse BT2 terminal .
Possible causes ness
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 and CK1
in normal state (female)
contact)
Wiring harness between DPC2A (female)
and CK1 (female)
Between Operate (Press) the machine mon-
Resistance 20 – 30 V
DPC2A itor check switch.
and chas- Do not operate (Release) the ma-
sis ground Resistance Max. 1 V
chine monitor check switch.
HD465-7, HD605-7 20-929

➀
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY

a) Machine monitor mode select switch 1 system is abnormal
Action code Error code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 1 system is abnormal
• Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
Contents of trouble
system is abnormal.)
Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
appears on machine system is abnormal.)

2) Disconnect connector CH1.
Between Press [ ] of the machine monitor Resistance Max. 1 Ω
Machine monitor mode se- CH1 select switch 1.
1 lect switch 1 system defec- (male) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select Resistance Min. 1 M Ω
CH1 switch in NEUTRAL.
(male) Press [ ] of the machine monitor
and Resistance Max. 1 Ω
select switch 1.
2) Disconnect connectors DPC2A, CH1, and fuse BT2 terminal .
Disconnection in wiring har- Wiring harness between fuse BT2 and CH1
2 (female)
and CH1 (female)
and CH1 (female)
and standard value 2) Disconnect connectors DPC2A and CH1.
Voltage between
Wiring harness between DPC2A DPC2A (female) ,
Short circuit with power Max. 1 V
3 (female) and CH1 (female) CH1 (female) and
chassis ground
Voltage between
Max. 1 V
(female) and CH1 (female) CH1 (female) and
chassis ground
Between Press [ ] of the machine monitor Voltage 20 – 30 V
4 Machine monitor defective DPC2A select switch 1.
and chas- Set the machine monitor select
sis ground switch in NEUTRAL. Resistance Max. 1 V
Between Set the machine monitor select Resistance Max. 1 V

DPC2A switch in NEUTRAL.
and chas- Press [ ] of the machine monitor
sis ground select switch 1. Resistance 20 – 30 V
20-930 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-931

➀
b) Machine monitor mode select switch 2 system is abnormal
Action code Error code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 2 system is abnormal
• Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
Contents of trouble
system is abnormal.)
Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
appears on machine system is abnormal.)

2) Disconnect connector CH2.
Between Press [>] of the machine monitor Resistance Max. 1 Ω
Machine monitor mode se- CH2 select switch 2.
1 lect switch 2 system defec- (male) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select
CH2 switch in NEUTRAL.
(male) Press [<] of the machine monitor
and Resistance Max. 1 Ω
select switch 2.
2) Disconnect connectors DPC2A, CH2, and fuse BT2 terminal .
Disconnection in wiring har- Wiring harness between fuse BT2 and CH2
2 (female)
and CH2 (female)
and CH2 (female)
and standard value 2) Disconnect connectors DPC2A and CH2.
Voltage between
Short circuit with power Max. 1 V
3 (female) and CH2 (female) CH2 (female) and
chassis ground
Voltage between
Max. 1 V
(female) and CH2 (female) CH2 (female) and
chassis ground
Between Press [>] of the machine monitor Voltage 20 – 30 V
4 Machine monitor defective DPC2A select switch 2.
and chas- Set the machine monitor select
sis ground switch in NEUTRAL. Resistance Max. 1 V
Between Set the machine monitor select

Resistance Max. 1 V
DPC2A switch in NEUTRAL.
and chas- Press [<] of the machine monitor
sis ground Resistance 20 – 30 V
select switch 2.
20-932 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-933

➀
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY

Trouble Power mode select function does not work normally
Not set Not set MON
• When the power mode select switch is operated, the power mode select function does not work nor-
Contents of trouble
mally.
Problem that • When the power mode select switch is operated, the power mode select function does not work nor-
appears on machine mally.

2) Disconnect connector PWM.
Set the power mode select switch
Power mode select switch
1 Between in ECONOMY MODE (Press its Resistance Min. 1 M Ω
defective
PWM upper part).
(male) Set the power mode select switch
and in HIGH POWER MODE (Press its Resistance Max. 1 Ω
lower part: Normal work).
2) Disconnect connectors DPC2A, PWM, and fuse BT2 terminal .
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 and
in normal state PWM (female)
contact)
and PWM (female)
3 Machine monitor defective Set the power mode select switch
Between in ECONOMY MODE (Press its Voltage 20 – 30 V
DPC2A upper part).
and chas- Set the power mode select switch
sis ground in HIGH POWER MODE (Press its Voltage Max. 1 V
lower part: Normal work).
20-934 HD465-7, HD605-7

➀
MON-8 SEAT BELT CAUTION LAMP DOES NOT OPERATE NORMALLY

a) Lamp lights up while seat belt is fastened
Action code Error code Controller code Seat belt caution lamp does not operate normally
Trouble
Not set Not set Not set a) Lamp lights up while seat belt is fastened
Contents of trouble • The lamp lights up while the seat belt is fastened.
Problem that
• The lamp lights up while the seat belt is fastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 Ω
and Seat belt "Unfastened" Resistance Min. 1 M Ω
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal .
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 and SBS
in normal state (female)
contact)
Wiring harness between DPC2B (female)
and SBS (female)
2) Disconnect connector DPC2B.
3 Machine monitor defective 4) Connect the connector.
Between DPC2B Seat belt "Fastened" Voltage 20 – 30 V
and chassis ground Seat belt "Unfastened" Voltage Max. 1 V
HD465-7, HD605-7 20-935

➀
b) Lamp does not light up while seat belt is unfastened
Action code Error code Controller code Seat belt caution lamp does not operate normally
Trouble
Not set Not set MON b) Lamp does not light up while seat belt is unfastened
Contents of trouble • The lamp does not light up while the seat belt is unfastened.
Problem that
• The lamp does not light up while the seat belt is unfastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 Ω
and Seat belt "Unfastened" Resistance Min. 1 M Ω
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal .
Possible causes Disconnection in wiring har- 3) Connect T-adapter.
and standard value 2 ness Voltage between
contact) Wiring harness between DPC2B DPC2B (female) ,
Max. 1 V
(female) and SBS (female) SBS (female) and
chassis ground
Between DPC2B Seat belt "Fastened" Voltage 20 – 30 V
and chassis ground Seat belt "Unfastened" Voltage Max. 1 V
20-936 HD465-7, HD605-7

➀
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY

a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Action code Error code Controller code Turn signals and hazard lamp do not operate normally
Trouble a) When turn signal lever and hazard lamp switch are operated,
Not set Not set Not set any turn signal lamp does not flash
Contents of trouble • When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Problem that
• When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
appears on machine
• Before performing troubleshooting, check that fuse BT2 and BT3 are not broken. (If either or
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
• The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the
wiring harness on the signal side (between the branching point and lamp), and defect of the wiring har-
ness on the GND side.

When hazard relay 2 (R17) is re- No Relay (R17) is normal
3) Check the relay.
Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF.

tive
3) Check the relay.
Possible causes 4) Apply voltage between R17 (male) and .
tween and .
Apply 24 V between
tween and .
2) Disconnect connectors R17, FLB, FLL, CM, and R16.
ness
2 Between R17 (female) and FLB Resistance Max. 1 Ω
contact) Wiring harness between FLL and CM (female)
and branching point of R16 (female) and Resistance Max. 1 Ω
HD465-7, HD605-7 20-937

➀
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
light up
Trouble b) When turn signal lever and hazard lamp switch are operated,
Not set Not set MON the turn signal lamps do not flash but light up
• When the turn signal lever and lamp hazard switch are operated, the turn signal lamps do not flash but
Contents of trouble
light up
Problem that • When the turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
appears on machine light up
Related information both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)

2) Disconnect connectors R17, FLB, FLL, CM, and R16.
Short circuit with power Resistance value be-
1
source in wiring harness Wiring harness between FLL, CM tween FLL, CM (fe-
Possible causes (female) , and R16 (female) male) , R16 Max. 1 Ω
and standard value and (female) , and
in normal state chassis ground
2) Replace the flasher.
2 Flasher defective If the flasher is replaced, the failure is not re-
Flasher is normal
paired.
If the flasher is replaced, the failure is repaired. Flasher is defective
20-938 HD465-7, HD605-7

➀
c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash
(When hazard lamp switch is operated, however, turn signal lamps flash normally)
c) When turn signal lever is operated, turn signal lamps on either
Trouble
Not set Not set MON or both sides do not flash (When hazard lamp switch is oper-
ated, however, turn signal lamps flash normally)
• When the turn signal lever is operated, the turn signal lamps on either or both sides do not flash (When
Contents of trouble
the hazard lamp switch is operated, however, the turn signal lamps flash normally)
Problem that • When the turn signal lever is operated, however, the turn signal lamps on either or both sides do not
appears on machine flash (When the hazard lamp switch is operated, the turn signal lamps flash normally)

2) Disconnect connector CM.
3) Check the lever.
Set the turn signal le-
Between CM (male) ver in LEFT.
1 Turn signal lever defective and Set the turn signal le-
ver in RIGHT.
Set the turn signal le-
Between CM (male) ver in LEFT.
and Set the turn signal le-
ver in RIGHT.
and standard value Between R17 (male) and Resistance 200 – 400 Ω
in normal state
tive
3) Check the relay.
Apply 24 V between
tween and .
Apply 24 V between
tween and .
2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
Disconnection in wiring har- minal .
3
(Disconnection or defective Wiring harness between fuse BT1 , R17 (fe-
contact) male) , and FLB
Wiring harness between CM (female) , FLL,
and branching point of R16 (female) and
HD465-7, HD605-7 20-939

➀
d) When hazard lamp switch is turned ON, any turn signal lamp does not flash
(When turn signal lever is operated, however, turn signal lamps flash normally)
d) When hazard lamp switch is turned ON, any turn signal lamp
Trouble
Not set Not set MON does not flash (When turn signal lever is operated, however,
turn signal lamps flash normally)
• When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
Contents of trouble
is operated, however, turn signal lamps flash normally).
Problem that • When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
appears on machine is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 Ω
HAZ
(male)
Turn the hazard lamp switch OFF. Resistance Min. 1 M Ω
and
3) Check the relay.

Possible causes 2 2) Disconnect connector R16.
and standard value tive
3) Check the relay.
in normal state 4) Apply voltage between R16 (male) and .
Apply 24 V between
tween and .
Apply 24 V between
tween and .
Hazard relay 2 (R17) defec- placed, is failure repaired?
3 Yes Relay (R17) is defective
tive
3) Check the relay.
20-940 HD465-7, HD605-7

➀

3) Check the relay.
Apply 24 V between
Hazard relay 2 (R17) defec- Between R17 (male) and .
3 and
tive Do not apply 24 V be-
tween and .
Apply 24 V between
tween and .
Possible causes 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
and standard value minal .
Wiring harness between fuse BT1 and R17
(female)
Wiring harness between FLL and R16 (female)
and
(Disconnection or defective chassis ground
contact) Wiring harness between R17 (female) and
chassis ground
Wiring harness between fuse BT2 and HAZ
(female)
Wiring harness between HAZ (female) and
R16 (female)
Wiring harness between HAZ (female) and
R17 (female)
HD465-7, HD605-7 20-941

➀
e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing
(When turn signal lever is operated, however, turn signal lamps flash normally)
e) When hazard lamp switch is turned OFF, turn signal lamps
Trouble
Not set Not set MON continue flashing (When turn signal lever is operated, howev-
er, turn signal lamps flash normally)
• When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
Contents of trouble
lever is operated, however, turn signal lamps flash normally).
Problem that • When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
appears on machine lever is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 Ω
HAZ
(male)
Turn the hazard lamp switch OFF. Resistance Min. 1 M Ω
and
3) Check the relay.

tive
in normal state
Apply 24 V between
tween and .
Apply 24 V between
tween and .
2) Disconnect connectors HAZ, R17, and R16.
Voltage between HAZ
Short circuit with power Wiring harness between HAZ (fe- (female) , R16 (fe-
3 Max. 1 V
source in wiring harness male) and R16 (female) male) and chassis
ground
Voltage between HAZ
Wiring harness between HAZ (fe- (female) , R17 (fe-
Max. 1 V
ground
20-942 HD465-7, HD605-7

➀
f) Turn signal pilot lamps do not flash normally

(Turn signal lamps flash normally, however)
Trouble f) Turn signal pilot lamps do not flash normally (Turn signal
Not set Not set MON lamps flash normally, however)
Contents of trouble • The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
Problem that
• The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
appears on machine
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
• The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the

2) Disconnect connectors BTC2A and R16.
ness
1 Wiring harness between DPC2A (female)
and R16 (female)
contact)
and R16 (female)
Between Set the turn signal lever in RIGHT. Max. 1 V /
Voltage
DPC2A 20 – 30 V (*)
2 Machine monitor defective and chas- Set the turn signal lever in NEU-
sis ground TRAL. Voltage Max. 1 V
Between Set the turn signal lever in NEU- Voltage Max. 1 V

DPC2A TRAL.
and chas- Max. 1 V /
sis ground Set the turn signal lever in LEFT. Voltage
20 – 30 V (*)
(*) Voltage changes alternately.
HD465-7, HD605-7 20-943

➀
20-944 HD465-7, HD605-7

➀
MON-10 NIGHT LIGHTING IS ABNORMAL

a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does
not light up.
Action code Error code Controller code Night lighting is abnormal

Trouble a) When lamp switch is set in 1st or 2nd position, any of small
Not set Not set Not set lamp, night lamp, and head lamp does not light up.
• When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
Contents of trouble
lamp does not light up.
Problem that • When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
appears on machine lamp does not light up.
• Before performing troubleshooting, check that fuses BT1 , BT1 , BT1 , BT1 , and BT1
are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related
wiring harness.)
• The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly,
Related information
if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the

Between Set the lamp switch in OFF position. Resistance Min. 1 M Ω

1 Lamp switch defective CM (male) Set the lamp switch in 1st position. Resistance Max. 1 Ω
and Set the lamp switch in 2nd position. Resistance Max. 1 Ω
Possible causes
and standard value Between Set the lamp switch in OFF position. Resistance Min. 1 M Ω
in normal state CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M Ω
Disconnection in wiring har- 2) Disconnect connectors CM and fuse BT1
ness 3) Insert T-adapter.
2
(Disconnection or defective 4) Turn the starting switch ON.
contact) Wiring harness between BT1 Voltage between CM
20 – 30 V
and CM (female) and chassis ground
HD465-7, HD605-7 20-945

➀
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up

Trouble b) When lamp switch is set in 1st position, small lamp and night
Not set Not set Not set lamp do not light up
Contents of trouble • When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
Problem that
• When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
appears on machine
wiring harness.)
Related information


Possible causes
and standard value
CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M Ω
in normal state
2) Disconnect connectors CM and fuse BT1
ness 4) Turn the starting switch ON.
2
contact) Wiring harness between CM (fe-
Voltage between CM
male) , DPC2B (female), and 20 – 30 V
and chassis ground
branching point of BT1 and
20-946 HD465-7, HD605-7

➀
c) When lamp switch is OFF, small lamp and night lamp light up

Trouble
Not set Not set MON c) When lamp switch is OFF, small lamp and night lamp light up
Contents of trouble • When the lamp switch is OFF, the small lamp and night lamp light up.
Problem that
• When the lamp switch is OFF, the small lamp and night lamp light up.
appears on machine

Possible causes Between Set the lamp switch in OFF position. Resistance Min. 1 M Ω
and standard value CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M Ω
in normal state and Set the lamp switch in 2nd position. Resistance Max. 1 Ω
2) Disconnect connectors DPC2B, CM, LS, fuse BT1 , and ta-
chograph.
Short circuit with power 3) Connect T-adapter.
source in harness
Wiring harness between CM (fe- Voltage between CM
male) , DPC2B (female), and (female) and chas- Max. 1 V
branching point of BT1 and sis ground
HD465-7, HD605-7 20-947

➀
d) When dimmer switch is operated, brightness of night lighting does not change

Trouble d) When dimmer switch is operated, brightness of night lighting
Not set Not set Not set does not change
Contents of trouble • When the dimmer switch is operated, the brightness of the night lighting does not change.
Problem that
• When the dimmer switch is operated, the brightness of the night lighting does not change.
appears on machine
wiring harness.)
Related information

2) Disconnect connectors DPC2B, CM, fuse BT1 and , Switch,
and Tachograph.
Wiring harness between LS (female) and
1 chassis ground
contact) Wiring harness between LS (female) and
DPC2B (female) (branching point of Resistance Max. 1 Ω
Possible causes Switch)
and standard value
Wiring harness between LS (female) and
in normal state
DPC2B (female) (branching point of BT1 Resistance Max. 1 Ω
and and Tachograph)
2 Dimmer switch defective 5) Turn the starting switch ON.
6) Set the lamp switch in 1st position.
Between LS and Voltage 20 – 30 V
Between LS and Voltage 6 – 27 V
20-948 HD465-7, HD605-7

➀
e) Head lamp "Hi" beam does not light up

Trouble
Not set Not set Not set e) Head lamp "Hi" beam does not light up
Contents of trouble • The head lamp cannot be set to "Hi" or "Lo".
Problem that
• The head lamp cannot be set to "Hi" or "Lo".
appears on machine
wiring harness.)
Related information


When head lamp "Lo" relay (R30) is No Relay R30
replaced, is failure repaired? Yes Relay R30
3) Check the relay.
Possible causes Head lamp "Hi" relay (R30)
and standard value 2 defective Between R30 (male) and Resistance 200 – 400 Ω
3) Check the relay.
Apply 24 V between
tween and .
2) Disconnect connectors DPC2B, CM, fuse BT1 and , Switch,
and Tachograph
ness
3
(Disconnection or defective Wiring harness between R30 (female) , Resistance Max. 1 Ω
contact) and branching point of wiring harness
DCP1 (female)
branching point of wiring harness
HD465-7, HD605-7 20-949

➁
f) Head lamp "Lo" beam does not light up

Trouble
Not set Not set Not set f) Head lamp "Lo" beam does not light up
Contents of trouble • The head lamp "Lo" beam does not light up.
Problem that
• The head lamp "Lo" beam does not light up.
appears on machine
wiring harness.)
Related information


Possible causes
2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1
and standard value
terminals and
in normal state
Wiring harness between PL1 (female) and
chassis ground
Disconnection in wiring har- Wiring harness between PR1 (female) and
2 chassis ground
contact) Wiring harness between battery relay terminal
M (CN-02), fuse BT1 terminals and , and Resistance Max. 1 Ω
CM (female)
Wiring harness between CM (female) and
fuse BT1 terminal
Wiring harness fuse BT1 terminal and PL1
(female) , PR1 (female)
20-950 HD465-7, HD605-7

➁
g) Head lamp cannot be set to "Hi" or "Lo"

Trouble
Not set Not set Not set g) Head lamp cannot be set to "Hi" or "Lo"
Contents of trouble • The head lamp "Hi" beam does not light up.
Problem that
• The head lamp "Hi" beam does not light up.
appears on machine
wiring harness.)
Related information

1 Passing switch defective Set the passing switch in RAISE
Between (PASS) position. Resistance Max. 1 Ω
CM (male)
Set the passing switch in RETURN
(OFF) position.
When head lamp "Hi" relay (R29) No Relay R29
is replaced, is failure repaired? Yes Relay R29
3) Check the relay.
Head lamp "Passing" relay
2
3) Check the relay.
Possible causes 4) Apply voltage between R29 (male) and .
tween and .
2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1
terminals and
Wiring harness between PL2 (female) and
chassis ground
Wiring harness between PR2 (female) and
chassis ground
ness Wiring harness between fuse BT1 terminal
(Disconnection or defective and PL2 (female) , PR2 (female)
contact) Wiring harness between R29 (female) and
chassis ground
R29 (female)
HD465-7, HD605-7 20-951

➁
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up

Trouble h) When head lamp is set to "Hi" beam, pilot lamp of machine
Not set Not set Not set monitor does not light up
Contents of trouble • When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
Problem that
• When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
appears on machine
wiring harness.)
Related information

Disconnection in wiring har- 2) Disconnect connectors DPC2A, CM, and R29.
1
Wiring harness between DPC2A (female) ,
CM (female) , and R29 (female)
and standard value 2) Disconnect connector DPC2A.
in normal state 3) Insert T-adapter.
Set the passing switch
Voltage Max. 1 V
Between DPC2A in "Lo".
and chassis ground Set the passing switch
Voltage 20 – 30 V
in "Hi".
20-952 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-953

➁
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY

a) Operating left side does not
Action code Error code

Controller code Power window does not operate normally
Trouble
Not set Not set Not set a) Operating left side does not
Contents of trouble • The power window does not operate normally. (Operating left side does not)
Problem that
• The power window does not operate normally. (Operating left side does not)
appears on machine
• Before performing troubleshooting, check that fuses BT2 are not broken. (If any of them is broken,
Related information
there is a grounding fault. Accordingly, check the related wiring harness.)

Power window switch (L.H.) "Left
Between Resistance Min. 1 M Ω
up"
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M Ω
Power window switch (L.H.) (male)
1 and Power window switch (L.H.) "Left
defective Resistance Max. 1 Ω
down"
Power window switch (L.H.) "Left
Between Resistance Max. 1 Ω
up"
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M Ω
(male)
and Power window switch (L.H.) "Left
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R34, PWL, and fuse BT2 terminal .
and standard value 4) Connect the connectors.
and R34 (female)
Disconnection in wiring har- and R25 (female)
(Disconnection or defective R34 (female)
contact)
CAB1 and PWL (female)
CAB1 and PWL (male)
R34 (female)
chassis ground
2) Replace power window motor (L.H.) with motor normal one.
Power window motor (L.H.) ★ If the results of 1 – 3 above are normal, perform the following test.
4
defective
When power window motor (L.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
20-954 HD465-7, HD605-7

➁
b) Operating right side does not
Action code Error code Controller code Power window does not operate normally
Trouble
Not set Not set Not set b) Operating right side does not
Contents of trouble • The power window does not operate normally. (Operating right side does not)
Problem that
• The power window does not operate normally. (Operating right side does not)
appears on machine
• Before performing troubleshooting, check that fuses BT2 are not broken. (If any of them is broken,
Related information
there is a grounding fault. Accordingly, check the related wiring harness.)

Power window switch (R.H.) "Right
Between Resistance Min. 1 M Ω
up"
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M Ω
Power window switch (R.H.) (male)
1 and Power window switch (R.H.) "Right
defective Resistance Max. 1 Ω
down"
Power window switch (R.H.) "Right
Between Resistance Max. 1 Ω
up"
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M Ω
(male)
and Power window switch (R.H.) "Right
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R35, PWR, and fuse BT2 terminal .
and standard value 4) Connect the connectors.
and R35 (female)
Disconnection in wiring har- and R25 (female)
(Disconnection or defective R35 (female)
contact)
CAB1 and PWR (female)
CAB1 and PWR (male)
R35 (female)
chassis ground
2) Replace power window motor (R.H.) with motor normal one.
Power window motor (R.H.) ★ If the results of 1 – 3 above are normal, perform the following test.
4
defective
When power window motor (R.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
HD465-7, HD605-7 20-955

➁
20-956 HD465-7, HD605-7

➁
MON-12 DEFECTIVE AIR CONDITIONER

a) Air conditioner does not operate
Action code Error code Controller code Defective air conditioner

Trouble
None None None a) Air conditioner does not operate
Contents of trouble • The air conditioner does not operate.
Problem that
• The air conditioner does not operate.
appears on machine
• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information
grounding fault.

2) Disconnect connector ACP1 and fuse BT3 (4) terminal.
1 Wiring harness between fuse BT3 (4) and
and standard value (Disconnection or defective Resistance Max. 1 Ω
ACP1 (female) (1)
in normal state contact)
Wiring harness between ACP1 (female) (14)
and chassis ground
a Check the control panel and repair or replace it, if it has abnormality.
Defective air conditioner
2
control panel
HD465-7, HD605-7 20-957

➄
b) Air does not come out or air flow cannot be adjusted

Trouble
None None None b) Air does not come out or air flow cannot be adjusted
Contents of trouble • Air does not come out or air flow cannot be adjusted
Problem that
• Air does not come out or air flow cannot be adjusted
appears on machine
Related information

2) Disconnect connectors ACR1, ACR2, ACR3, and ACR4 and fuse
terminals BT1 (18) and BT3 (4).
Wiring harness between fuse BT3 (4) and
ACR1 (female) (1)
Disconnection in power
supply wiring harness Wiring harness between fuse BT3 (4) and
(Disconnection or defective ACR2 (female) (1)
contact) Wiring harness between fuse BT3 (4) and
ACR3 (female) (1)
ACR4 (female) (1)
ACR1 (female) (3)
2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
and ACR1 (female) (2)
Possible causes
and standard value Wiring harness between ACP1 (female) (5)
in normal state and ACR2 (female) (2)
Wiring harness between ACR1 (female) (4)
Disconnection in wiring Resistance Max. 1 Ω
harness and ACBM (female) (1)
2
(Disconnection or defective Wiring harness between ACR2 (female) (3)
contact) and ACBM (female) (2), ACRE (female) (1)
and ACRE (female) (2)
and ACRE (female) (3)
wiring harness between ACR2 (female) (4)
and chassis ground
and chassis ground
and chassis ground)
wiring harness between ACRE (female) (4)
and chassis ground
20-958 HD465-7, HD605-7

➄

2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Wiring harness between Resistance between ACR1
ACR1 (female) (4) and (female) (4), ACBM (female) Min. 1 M Ω
ACBM (female) (1) (1) and chassis ground
3 ACR2 (female) (3) and (female) (3), ACBM (female)
harness Min. 1 M Ω
ACBM (female) (2), ACRE (2), ACRE (female) (1) and
(female) (1) chassis ground
ACR3 (female) (3) and (female) (3), ACRE (female) Min. 1 M Ω
ACRE (female) (2) (2) and chassis ground
ACR4 (female) (3) and (female) (3), ACRE (female) Min. 1 M Ω
ACRE (female) (3) (3) and chassis ground
2) Replace relay.
4 Defective blower main relay 4) Start air conditioner.
Replace relay Condition becomes normal. Relay is defective.
with normal one. Condition does not become normal. Relay is normal.
2) Replace relay.
5 Defective blower Hi relay 4) Start air conditioner.
Possible causes Condition becomes normal. Relay is defective.
Replace relay
and standard value
in normal state
2) Replace relay.
6 Defective blower M2 relay 4) Start air conditioner.
2) Replace relay.
7 Defective blower M1 relay 4) Start air conditioner.
2) Replace motor.
8 Defective blower motor 4) Start air conditioner.
Replace motor Condition becomes normal. Relay is defective.
2) Disconnect connector ACRE.
3) Check resistor unit.
9 Defective blower resistor Between ACRE (female) (1) and (2) Resistance 2.8 Ω
Between ACRE (female) (1) and (3) Resistance 4.8 Ω
Between ACRE (female) (1) and (4) Resistance 4.0 Ω
10
control panel
HD465-7, HD605-7 20-959

➄
c) Air is not cooled or temperature cannot be adjusted (Electric system)

Trouble c) Air is not cooled or temperature cannot be adjusted (Electric
None None None system)
Contents of trouble • Air is not cooled or temperature cannot be adjusted (Electric system)
Problem that
• Air is not cooled or temperature cannot be adjusted (Electric system)
appears on machine
• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information grounding fault. If fuse BT1 (18) is broken, check the wiring harness between fuse BT1 (18) and ACR5
(female) (3) for grounding fault.

2) Disconnect connectors ACR5 and fuse terminals BT1 (18) and BT3 (4).
Disconnection in power 3) Connect T-adapter.
supply wiring harness
1 Wiring harness between fuse BT3 (4) and
ACR5 (female) (1)
contact)
ACR5 (female) (3)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
and ACPS (female) (2)
and ACTH (female) (1)
and ACM1(female) (4)
Disconnection in wiring har- and ACTH (female) (2) Resistance Max. 1 Ω
2 ness (Disconnection or de-
fective contact) Resistance Max. 1 Ω
Possible causes and ACM1 (female) (3)
and standard value Wiring harness between ACP1 (female) (16)
and ACM1 (female) (1)
and ACPS (female) (1)
and E07 (female) (1)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Wiring harness between Resistance between ACP1
ACP1 (female) (6) and (female) (6), ACPS (female) Min. 1 M Ω
Grounding fault in wiring ACPS (female) (2) (2) and chassis ground
3
harness
ACP1 (female) (9) and (female) (9), ACTH (female) Min. 1 M Ω
ACTH (female) (1) (1) and chassis ground
ACP1 (female) (10) and (female) (10), ACM1 (female) Min. 1 M Ω
ACM1 (female) (4) (4) and chassis ground
20-960 HD465-7, HD605-7

➄

ACP1 (female) (13) and (female) (13), ACTH (female) Min. 1 M Ω
ACTH (female) (2) (2) and chassis ground
ACP1 (female) (13) and (female) (13), ACM1(female) Min. 1 M Ω
Grounding fault in wiring ACM1 (female) (2) (2) and chassis ground
3
harness
ACR5 (female) (2) and (female) (2), ACPS (female) Min. 1 M Ω
ACPS (female) (1) (1) and chassis ground
ACR5 (female) (4) and E07 (female) (4), E07 (female) Min. 1 M Ω
(female) (1) (1) and chassis ground
2) Replace relay.
Defective compressor clutch
4 4) Start air conditioner.
Possible causes relay
and standard value Replace relay Condition becomes normal. Relay is defective.
in normal state with normal one. Condition does not become normal. Relay is normal.
2) Disconnect connector ACPS.
5 Defective pressure switch
Between ACPS Air conditioner switch OFF Resistance Min. 1 M Ω
(male) (1) and Air conditioner switch ON in
(2) Resistance Max. 1 Ω
cooling mode
2) Disconnect connector ACTH.
6 Defective thermistor 4) Start air conditioner.
Between ACTH (male) Temperature: 25°C Resistance 37 – 50 k Ω
(1) and (2) Temperature: 100°C Resistance 3.5 – 4.0 k Ω
2) Replace motor.
Defective temperature ad-
7 4) Start air conditioner.
justment servomotor
Replace motor Condition becomes normal. Motor is defective.
with normal one. Condition does not become normal. Motor is normal.
2) Replace air conditioner compressor.
Defective air conditioner 4) Start air conditioner.
8
compressor Replace air Condition becomes normal. Compressor is defective.
conditioner
compressor with Condition does not become Compressor is normal.
normal one. normal.
HD465-7, HD605-7 20-961

➄

2) Replace diode (E08).
Possible causes
9 Defective diode (E08) Replace diode Condition becomes normal. Diode (E08) is defective.
and standard value
in normal state (E08) with Condition does not become
normal one. Diode (E08) is normal.
normal.
10
control panel
d) Recirculated air and fresh air cannot be selected

Trouble
None None None d) Recirculated air and fresh air cannot be selected
Contents of trouble • Recirculated air and fresh air cannot be selected because of a defect in the air conditioner system.
Problem that
• Recirculated air and fresh air cannot be selected.
appears on machine
Related information

2) Disconnect connectors ACP2 and ACM3.
Disconnection in wiring 3) Connect T-adapter.
harness
1 Wiring harness between ACP2 (female) (5)
contact)
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors ACP2 and ACM3.
2 ACP2 (female) (5) and (female) (5), ACM3 (female) Min. 1 M Ω
harness
3
control panel
20-962 HD465-7, HD605-7

➄
e) Air outlets cannot be selected

Trouble
None None None e) Air outlets cannot be selected
Contents of trouble • Air outlets cannot be selected
Problem that
• Air outlets cannot be selected
appears on machine
Related information

2) Disconnect connectors ACP1, ACP2, and ACM2.
Disconnection in wiring Wiring harness between ACP1 (female) (13)
harness Resistance Max. 1 Ω
1 and ACM2 (female) (3)
2) Disconnect connectors ACP1, ACP2, and ACM2.
and standard value
in normal state
Grounding fault in wiring ACM2 (female) (3) (3) and chassis ground
2
harness Wiring harness between Resistance between ACP2
3
control panel
HD465-7, HD605-7 20-963

➄
20-964 HD465-7, HD605-7

➄
f) Air is not cooled (Mechanical system)

Trouble
None None None f) Air is not cooled (Mechanical system)
Contents of trouble • Air is not cooled because of abnormality in mechanical system.
Problem that
• Air is not cooled because of abnormality in mechanical system.
appears on machine
Related information

Gas leakage through pipe
1 • Check and repair or replace, if abnormal.
joints or parts
Natural leakage through
hose, etc. (Refrigerant has • Check refrigerant level and add new refrigerant to proper level, if nec
2
not been added for long essary.
time)
3 Insufficient refrigerant level • Add new refrigerant to proper level.
a Check the valve for excessive opening and defective contact of

• Check and repair or replace, if abnormal.
4 Defective expansion valve
heat-sensor tube, too.
Clogging of low-pressure
5 • Check and remove clogging material, if there is any, or replace.
circuit and evaporator
• Check and remove clogging material, if there is any, and clean evap-
Possible causes 6 Clogging of evaporator fins
orator.
and standard value
in normal state 7 Clogging of filter • Check and clean, or replace.
Defective installation of ther-
mistor
Air leakage through air con-
9 • Check and repair or replace leaking part.
ditioner unit and duct
10 Insufficient set air flow • Increase set air flow.
11 Excessive refrigerant • Check refrigerant level and reduce it to proper level, if necessary.
• Evacuate system and fill it with refrigerant to proper level and replace
12 Entry of air
receiver drier.
13 Clogging of condenser fins • Check fins for clogging and clean them, if necessary.
Insufficient compression by
14 • Check and repair or replace, if necessary.
compressor
Entry of water in refrigerant • Evacuate system and fill it with refrigerant to proper level and replace
15
circuit receiver drier.
HD465-7, HD605-7 20-965

➄
g) Air is not heated (Defective hot water circuit)

Trouble
None None None g) Air is not heated (Defective hot water circuit)
Contents of trouble • Air is not heated (Defective hot water circuit).
Problem that
• Air is not heated (Defective hot water circuit).
appears on machine
• Check that water is not leaking through the hot water circuit.
Related information
• Check that air is flowing out of the air outlets.
1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet
• Check heater core fins for clogging and clean them, if necessary.
of the heater core becomes high.
a If this is the cause, the temperature at the hot water inlet and outlet
• Check and repair or replace leaking part.
Air leakage through air con-
2
ditioner unit
of the heater core becomes high.
a If this is the cause, the temperature at the hot water inlet of the heat-
Possible causes • Check and remove clogging material, or replace valve.
and standard value 3 Defective water valve
in normal state (Clogging or defective valve)
er core becomes high but that at the hot water outlet becomes low.
4 Clogging of heater core
er core becomes high but that at the hot water outlet becomes low.
Clogging up to hot water
5
inlet of heater core
er core becomes low.
h) Abnormal sound comes out
Action code Controller code

Error code Defective air conditioner
Trouble
None None None h) Abnormal sound comes out
Contents of trouble • Abnormal sound comes out.
Problem that
• Abnormal sound comes out.
appears on machine
Related information

Defective installation of bolts
1 • Check and repair, if abnormal.
(screws) related to case
Interference of fan case, etc.
or breakage of fan
Entry of foreign matter in
Possible causes 3 blower motor or defective • Check and remove foreign matter, if there is any, and repair or replace
and standard value blower motor
in normal state • Check and replace, if abnormal sound (peep or gas leakage sound)
4 Defective expansion valve
comes out.
Loosened or worn
5 • Check and repair or replace, if loosened or worn.
compressor V-belt
Insufficient or excessive • Check refrigerant level and reduce or increase it to proper level, if
6
refrigerant necessary.
7 Defective compressor • Check and repair or replace, if abnormal.
20-966 HD465-7, HD605-7

➄
i) Water leaks

Trouble
None None None i) Water leaks
Contents of trouble • Water leaks.
Problem that
• Water leaks.
appears on machine
Related information

Clogging of water drain hole
1 • Check and repair, if abnormal.
in air conditioner unit
Clogging, bend, defective
installation, or breakage of
drain hose of air conditioner
unit
Possible causes Breakage (Cracking) of air
and standard value 3 conditioner unit case • Check and repair or replace, if broken (cracked).
in normal state
Defective installation of bolts
4 (screws) related to air • Check and repair or replace, if abnormal.
conditioner unit case
Defective joints of hot water
circuit piping
6 Defective heater core • Check and repair or replace, if abnormal.
7 Defective water valve • Check and repair or replace, if abnormal.
HD465-7, HD605-7 20-967

➄
TROUBLESHOOTING OF VHMS CONTROLLER
SYSTEM (VHMS MODE)
Electrical system diagram related VHMS controller .................................................................................. 20-1002
Information given in troubleshooting chart ................................................................................................ 20-1004
Failure type code list ................................................................................................................................. 20-1005
[A000N1] (or VHMS_LED displays [n201]) Engine overrun ............................................................. 20-1006
[DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage.................................. 20-1006-1
[DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.... 20-1006-3
[DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24V) system... 20-1006-5
[DBB7KP] (or VHMS_LED indicates "n903") Abnormality in sensor power source (12V) system... 20-1006-7
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications:
Defective communications (KR)
(between engine controller and VHMS controller)............................................................ 20-1007
[DBBSKR] (or VHMS_LED displays [n803]) Defective S-NET communications: (KR) ...................... 20-1009
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground
in engine oil temperature sensor system (KB) {30 min (at 500 rpm or above) after
starting engine}..................................................................................................................20-1011
[DGE1KY] (or VHMS_LED displays [n241]) Short circuit with power source in engine
oil temperature sensor system (KY) ................................................................................. 20-1012
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system:
Input signal outside range (KX) ........................................................................................ 20-1013
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground
in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ........................................ 20-1014
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source in No. 1, 2, 3 (front)
exhaust temperature sensor system (KB) ........................................................................ 20-1016
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground
in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA) ......................................... 20-1018
[DGT5KB] (or VHMS LED displays [n321]) Short circuit with power source in No. 4, 5, 6 (rear)
exhaust temperature sensor system (KB) ........................................................................ 20-1020
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground
in engine blow-by pressure sensor system (KA) .............................................................. 20-1022
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source in engine
blow-by pressure sensor system (KY).............................................................................. 20-1023
[DhP4KX] Suspension pressure sensor (Front right): Out of input signal range (KX).................... 20-1023-1
[DhP5KX] Suspension pressure sensor (Front left): Out of input signal range (KX) ...................... 20-1023-3
[DhP6KX] Suspension pressure sensor (Rear right): Out of input signal range (KX) .................... 20-1023-5
[DhP7KX] Suspension pressure sensor (Rear left): Out of input signal range (KX)....................... 20-1023-7
[DKH1KX] Pitch angle sensor: Out of input signal range (KX)........................................................ 10-1023-9
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .......................... 20-1024
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (front) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1025
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (front) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1026
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (rear) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1027
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (rear) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1028
VHMS-1 VHMS-1 Abnormality in satellite data communication
a) Satellite communication data are not transmitted ......................................................... 20-1029
b) Abnormality in downloading into PC or setting of PC ................................................... 20-1032
VHMS-2 Abnormality in saving data in VHMS controller ................................................................. 20-1034
VHMS-3 Engine blow-by pressure indicated by monitor is low........................................................ 20-1036
HD465-7, HD605-7 20-1001

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
20-1002 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1003

➄
20-1003-1 HD465-7, HD605-7

➄
TROUBLESHOOTING INFORMATION GIVEN IN TROUBLESHOOTING CHART
INFORMATION GIVEN IN TROUBLESHOOTING CHART

★ The following type of information is given in the troubleshooting charts and related circuit diagrams, so make
sure that you understand the content fully before starting troubleshooting.
Shown on panel Shown on Shown on Trouble Problem that appeared on machine
display panel display panel display
Contents of trouble Condition when monitor panel or controller detected failure.
Action of controller Action taken to protect system or equipment when monitor panel or controller detected failure.
Problem that
Problem that appeared on machine when monitor panel or controller took above action.
appears on machine
Related information Information related to troubleshooting or failure that occurred.

<Content of information>
• Standard value when condition is normal (used to judge status of
probable failure).
1 • Remarks used to judge status of probable failure.
<Problems with wiring harness>

• Disconnection
Defective connection of connector or disconnection in wiring har-
ness.
2 • Short circuit with chassis ground
Wiring harness not connected to GND (ground) circuit is in contact
with GND circuit.
Wiring harness not connected to power source (24V) circuit is in
contact with power source circuit.
Probable cause Probable cause of existing • Short circuit
and standard value 3 failure (the numbers are Wiring harnesses of independent circuits are in abnormal contact.
when normal index numbers and do not
indicate the order of priority) <Precautions when troubleshooting>
Method of displaying connector No. and method of handling T-
adapter
If there are no special instructions, insert or connect the T-adapter
as follows.
4 • If there is no indication of (male) or (female) with the connector
No., disconnect the connector and insert the T-adapter into both
the male and female sides.
• If (male) or (female) is indicated with the connector No., discon-
nect the connector and insert the T-adapter into only the side indi-
cated (either male or female).
Order of listing pin No. and method of handling test lead
5 If there are no special instructions, connect the (+) lead and (–) lead
of the tester as follows.
• Connect the (+) lead to the pin No. or wiring harness given first.
• Connect the (–) lead to the pin No. or wiring harness given last.
20-1004 HD465-7, HD605-7

➁
TROUBLESHOOTING FAILURE TYPE CODE LIST
This is the section of the circuit diagram that shows the parts related to the failure.
• Connector No.: (type – No. of pins) (color).
• Arrows (⇔): Shows approximate mounting position on machine.
FAILURE TYPE CODE LIST

★ For failure type codes marked "See list", refer to this list.
Failure type Failure type
code Details of problem code Details of problem
Fill signal for non-existent combination of clutches ON simulta-

KA Disconnection L0 neously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
Drop in power source volt-
KK age, input L2 Fuel pressure is higher than max. specified value.
Mismatch in model selec-

KQ tion signal L3 Target components cannot be controlled.
KR Defective communications L4 ON/OFF signals from 2 systems do not match.

Engine speed signal, C terminal signal, oil pressure switch,
KT Abnormality inside con- L6 water temperature sensor signals do not match operating con-
troller dition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
KY source LC Speed signals of 2 systems do not match.
Disconnection or short cir- Switch remains pressed for length of time unthinkable for nor-
KZ cuit LD mal operations .
Fill signal is turned OFF when command current to ECMV is
MA Defective function LH ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
HD465-7, HD605-7 20-1005

➁
TROUBLESHOOTING [A000N1]
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN

Trouble Engine overrun
None A000N1 None
Contents of trouble • Engine speed of more than 2,625 rpm is detected when engine is running.
Action of controller • Carries out control for default mode.
Problem that
• If machine continues to be used as it is, engine may be damaged.
appears on machine
• Engine speed can be checked with monitoring function (code: 01001)
• LED display is [n201]
Related information
• If failure codes [C115KZ] or [C121LC] related to engine controller are displayed, carry out troubleshoot-
ing first for the applicable code.

1 Engine overrun Inspect engine and repair if any abnormality is found.
Defective engine speed
Probable cause 2 Carry out troubleshooting for failure code [C115KZ] or [C121LC].
sensor
and standard value
when normal 1) Start engine.
2) Check with monitoring function (code: 01001).
3 Defective VHMS controller
Monitoring code:
High idling speed Power mode 2,270 ± 50 rpm
01001
20-1006 HD465-7, HD605-7

➁
TROUBLESHOOTING [DBB0KK]
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE

VOLTAGE

Trouble Abnormality source voltage
None DBB0KK None
Contents of trouble • The switch source voltage is below 9.5(± 2.5)V or above 42.4(± 6)V.
Problem that
• The system may not operate normally.
appears on machine
Related information • VHMS controller LED indicates "n901".

• If the circuit breaker is turned OFF, the circuit probably has ground-
1 Defective circuit breaker
ing fault (See cause 3).
2) Disconnect connector HM-CN1 and battery relay terminal CN-02
(Terminal M).
Disconnection in wiring har- Wiring harness between HM-CN1 (female) (8),
2 ness (Disconnection or de- (9) and battery relay CN-02 (Terminal M) Resistance Max. 1 Ω
fective contact)
Wiring harness between HM-CN1 (female)
(11), (12) and ER
Probable cause Resistance Max. 1 Ω
(19), (20) and ER
and standard value
when normal
2) Disconnect connector HM-CN1, battery relay terminal CN-02
(Terminal M), and connectors related to them.
3 Wiring harness between Resistance between HM-
harness
HM-CN1 (female) (8), (9) CN1 (female) (8), (9) and
and battery relay CN-02 chassis ground Min. 1 M Ω
(Terminal M) and wiring har-
nesses related to it
2) Disconnect HM-CN1.
4 Defective VHMS controller 3) Connect T-adapter.
Between HM-CN1 (8), (9) and chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-1

➄
TROUBLESHOOTING [DBB0KK]
20-1006-2 HD465-7, HD605-7

➄
TROUBLESHOOTING [DBB5KP]
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER

SOURCE (5 V) SYSTEM

Trouble Abnormality in sensor power source (5 V) system
None DBB5KP None
Contents of trouble • Sensor power source (5 V) voltage is out of the normal range (4.5 – 5.5 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and HM-12.
harness
HM-CN1 (female) (4), (5) CN1 (female) (4), (5), HM-
Min. 1 M Ω
and HM-12 (female) (B) CN12 (female) (B) and chas-
sis ground
Probable cause 2) Disconnect connectors HM-CN1 and HM-12.
and standard value 3) Connect T-adapter.
when normal Short circuit with power 4) Turn starting switch ON.
2
source in wiring harness Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (4), (5) (female) (4), (5), HM-12 (fe-
Max. 1 V
and HM-12 (female) (B) male) (B) and chassis
ground
Between HM-CN1 (4), (5) and (11), (12) Voltage 4.5 – 5.5 V
HD465-7, HD605-7 20-1006-3

➄
20-1006-4 HD465-7, HD605-7

➄

SOURCE (24 V) SYSTEM

None DBB6KP None
Contents of trouble • Sensor power source (24 V) voltage is out of the normal range (20 - 30V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1, HM-23A, HM-23B, SUFR, SUFL,
SURR, and SURL.
Wiring harness between Resistance between HM-
HM-CN1 (female) (2) and CN1 (female) (2), HM-23A
Min. 1 M Ω
HM-23A (female) (A), HM- (female) (A), HM-23B (fe-
23B (female) (A) male) and chassis ground
harness
HM-CN1 (female) (2) and CN1 (female) (2), HM-SUFL
HM-SUFL (female) (B), HM- (female) (B), HM-SUFR (fe- Min. 1 M Ω
SUFR (female) (B) male) (B) and chassis
ground
Wiring harness between HM- Resistance between HM-
CN1 (female) (2) and HM- CN1 (female) (2), HM-SURL
Min. 1 M Ω
SURL (female) (B), HM- (female) (B), HM-SURR (fe-
SURR (female) (B) male) (B) and chassis ground
Probable cause 2) Disconnect connectors HM-CN1, GR-2, HM-23A, HM-23B, SUFR,
and standard value SUFL, SURR, and SURL.
when normal 3) Connect T-adapter.
Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (2) and (female) (2), HM-23A (fe-
Max. 1 V
HM-23A (female) (A), HM- male) (A), HM-23B (female)
Short circuit with power 23B (female) (A) (A) and chassis ground
2
source in wiring harness Voltage between HM-CN1
(female) (2), HM-SUFL (fe-
HM-CN1 (female) (2) and
male) (B), HM-SUFR (fe- Max. 1 V
HM-SUFL (female) (B), HM-
male) (B) and chassis
SUFR (female) (B)
ground
HM-CN1 (female) (2) and (female) (2), HM-SURL (fe-
Max. 1 V
HM-2SURL (female) (B), male) (B), HM-SURR (fe-
HM-SURR (female) (B) male) (B) and chassis ground
Between HM-CN1 (2) and (11), (12) Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-5

➄
20-1006-6 HD465-7, HD605-7

➄

SOURCE (12 V) SYSTEM

None DBB7KP None
Contents of trouble • Sensor power source (12 V) voltage is out of the normal range (10 – 15 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and GDL.
1 Resistance between HM-
CN1 (female) (3), GDL
HM-CN1 (female) (3) and Min. 1 M Ω
(male) (1) and chassis
GDL (male) (1)
ground
Probable cause
2) Disconnect connectors HM-CN1 and GDL.
and standard value
when normal Short circuit with power
HM-CN1 (female) (3) and (female) (3), GDL (male) (1) Max. 1 V
GDL (male) (1) and chassis ground
3 Defective VHMS controller 3) Insert T-adapter.
Between HM-CN1 (3) and (11), (12) Voltage 10 – 15V
HD465-7, HD605-7 20-1006-7

➄
20-1006-8 HD465-7, HD605-7

➄
TROUBLESHOOTING [DBBRKR]
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS:

DEFECTIVE COMMUNICATIONS (KR)
(BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)
Action code Error code Controller code Defective CAN communications: Defective communications (KR)
Trouble
None DBBRKR None (between engine controller and VHMS controller)
Contents of trouble • Communications (CAN) data from engine controller cannot be obtained.
Action of controller • Maintains condition existing when abnormality occurred.
Problem that
• VHMS function for obtaining data from engine controller not working.
appears on machine
Related information • If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first
for the applicable code.

2) Disconnect connectors HM-CN4A and CAN1.
harness
1 Wiring harness between HM-CN4A (female)
(disconnection, defective Resistance Max. 1 Ω
and CAN1 (female)
contact)
Wiring harness between HM-CN4A (female)
and CAN1 (female)
2) Disconnect connectors HM-CN4A and CAN1.
HM-CN4A (female) ,
Short circuit with chassis HM-CN4A (female) and Max. 1 Ω
2 CAN1 (female) – chassis
ground in wiring harness CAN1 (female)
ground
HM-CN4A (female) ,
Probable cause HM-CN4A (female) and Max. 1 Ω
CAN1 (female) – chassis
and standard value CAN1 (female)
ground
when normal
2) Disconnect connector HM-CN4A.
Short circuit with power Wiring harness between Voltage between HM-CN4A
3
source in wiring harness HM-CN4A (female) and (female) , CAN1 (female) Max. 1 V
CAN1 (female) – chassis ground
Wiring harness between Voltage between HM-CN4A
HM-CN4A (female) and (female) , CAN1 (female) Max. 1 V
CAN1 (female) – chassis ground
2) Replace VHMS controller.
4 Defective VHMS controller Does not communicate VHMS controller
Is communication normally normal
normal when VHMS
controller is replaced? Communicates VHMS controller
normally defective
HD465-7, HD605-7 20-1007

➁
TROUBLESHOOTING [DBBRKR]
20-1008 HD465-7, HD605-7

➁
TROUBLESHOOTING [DBBSKR]
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS:

(KR)

Trouble Defective S-NET communications: (KR)
E03 DBBSKR None
Contents of trouble • Communications data from controller cannot be obtained.
Action of controller • Machine monitor shows abnormal display screen (red) to warn operator of abnormality.
Problem that
• In some cases, system does not work normally.
appears on machine
• If failure code [DAQSKR], [DBISKR] related to S-NET of other controllers is displayed, carry out trou-
Related information bleshooting first for the applicable code.

2) Disconnect connectors HM-CN3A, JCB, JCC, and JCD.
Disconnection in wiring Wiring harness between HM-CN3A (female)
1 and JCB (female)
(disconnection, defective
and JCD (female)
, – JCC (female) , JCE (female)
2) Disconnect connectors HM-CN3A, JCB, and JCD.
HM-CN3A (female) , JCB
Short circuit with chassis HM-CN3A (female) and Min. 1 MΩ
2 (female) – chassis
ground in wiring harness JCB (female)
ground
Probable cause Resistance value between
and standard value Wiring harness between
HM-CN3A (female) , JCD
when normal HM-CN3A (female) and Min. 1 MΩ
(female) – chassis
JCD (female)
ground
2) Disconnect connector HM-CN3A, JCB, and JCD.
3 HM-CN3A (female) and (female) , JCB (female) Max. 1 V
JCB (female) – chassis ground
HM-CN3A (female) and (female) , JCD (female) Max. 1 V
JCD (female) – chassis ground
4 Defective VHMS controller 4) Connect connector.
Between HM-CN3A and Voltage Max. 6 – 9 V
Between HM-CN3A and Voltage Max. 6 – 9 V
HD465-7, HD605-7 20-1009

➁
TROUBLESHOOTING [DBBSKR]
20-1010 HD465-7, HD605-7

➁
TROUBLESHOOTING [DGE1KB]
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH

CHASSIS GROUND IN ENGINE OIL TEMPERUTURE SENSOR SYSTEM (KB)
{30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}
Action code Error code Controller code Disconnection, short circuit with chassis ground in engine oil
Trouble temperature sensor system (KB)
None DGE1KB None {30 min (at 500 rpm or above) after starting engine}
Contents of trouble • Signal voltage of engine oil temperature sensor has dropped below 0.3V.
Action of controller • Takes no particular action.
Problem that
• Engine oil temperature cannot be monitored with monitoring function.
appears on machine
• Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

2) Disconnect connector HM-31.
Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
Between HM-31 (male) 25 °C Resistance Approx. 35 – 50 kΩ
and 100 °C Resistance Approx. 3.3 – 4.3 kΩ
2) Disconnect connectors HM-CN2A and HM-31.
harness
Probable cause and HM-31 (female)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 Ω
and HM-31 (female)
2) Disconnect connector HM-CN2A and HM-31.
Short circuit with chassis
ground in wiring harness Wiring harness between
HM-CN2A (female) , HM-
HM-CN2A (female) and Min. 1 MΩ
HM-31 (female)
ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kΩ
HD465-7, HD605-7 20-1011

➁
TROUBLESHOOTING [DGE1KY]
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER

SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)
Action code Error code Controller code Short circuit with power source in engine oil temperature sensor
Trouble
None DGE1KY None system (KY)
Contents of trouble • Signal voltage of engine oil temperature sensor has risen above 4.9V.
Problem that
• Engine oil temperature cannot be monitored with monitoring function.
appears on machine
• Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch OFF.
Between HM-31 (male) 25 °C Resistance Approx. 35 – 50 kΩ
Probable cause 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors HM-CN2A and HM-31.
when normal Short circuit with power 3) Connect T-adapter.
2
source in wiring harness Wiring harness between Voltage between HM-CN2A
HM-CN2A (female) and (female) , HM-31 (female) Max. 1 V
HM-31 (female) – chassis ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kΩ
20-1012 HD465-7, HD605-7

➁
TROUBLESHOOTING [DGE5KX]
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE

SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)
Action code Error code Controller code Failure in ambient temperature sensor system: Input signal out-
Trouble
None DGE5KX None side range (KX)
Contents of trouble • Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.
Problem that
• Ambient temperature cannot be monitored with monitoring function.
appears on machine
• Ambient temperature can be checked with monitoring function (code: 37501).
Related information

Defective ambient
temperature sensor
0 °C Resistance Approx. 10 – 15 kΩ
Between HM-35 (male)
and
harness
Probable cause and HM-35 (female)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 Ω
and HM-35 (female)
Short circuit with chassis
ground in wiring harness Wiring harness between
HM-35 (female)
ground
4 Defective VHMS controller 0 °C Resistance Approx. 10 – 15 kΩ
Between HM-CN2A (female)
and
HD465-7, HD605-7 20-1013

➁
TROUBLESHOOTING [DGT4KA]
[DGT4KA] (OR VHMS_LED DISPLAYS [n312])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3
(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in No. 1, 2, 3
Trouble
None DGT4KA None (front) exhaust temperature sensor system (KA)
Contents of trouble • Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
• No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function.
appears on machine
• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
Related information
• LED display is [n312].

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor.
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
1 Does not become normal when replaced
exhaust temperature sensor normal
Exhaust temperature sensor
Becomes normal when replaced
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
2 exhaust temperature sensor 5) Start engine.
amp
Between and Voltage 20 – 30 V
HM-23A Between and 20 °C Voltage Approx. 0.9 – 1.2 V
500 °C Voltage Approx. 2.6 – 3.5 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Probable cause 3) Connect T-adapter.
and standard value
when normal Disconnection in wiring Resistance Max. 1 Ω
harness and HM-23A (female)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
and HM-23A (female)
Wiring harness between HM-22A (female)
and HM-21A (female)
Wiring harness between HM-22A (female)
and HM-21A (female)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Short circuit with chassis HM-CN1 (female) , HM-
4 HM-CN1 (female) and Min. 1 MΩ
ground in wiring harness 23A (female) – chassis
HM-23A (female)
ground
23A (female) – chassis
HM-23A (female)
ground
20-1014 HD465-7, HD605-7

➁

2) Disconnect connectors HM-CN1 and HM-CN2A.
Probable cause
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
Between HM-CN1 and HM-CN2A Voltage 20 – 30 V
Between HM-CN2A and 20 °C Voltage Approx. 0.9 – 1.2V
HD465-7, HD605-7 20-1015

➁
TROUBLESHOOTING [DGT4KB]
[DGT4KB] (OR VHMS_LED DISPLAYS [n311])

SHORT CIRCUIT WITH POWER SOURCE IN NO. 1, 2, 3 (FRONT) EXHAUST
TEMPERATURE SENSOR SYSTEM (KB)
Action code Error code Controller code Short circuit with power source in No. 1, 2, 3 (front) exhaust tem-
Trouble
None DGT4KB None perature sensor system (KB)
Contents of trouble • Signal voltage of more than 4.9V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
• No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function
appears on machine
Related information

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
amp
HM-23A Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21A and HM-22A.
Probable cause Short circuit with chassis
and standard value 3 ground in wiring harness Resistance value between
when normal HM-22A (female) ,
HM-22A (female) and Min. 1 MΩ
HM-21A (female) – chas-
HM-21A (female)
sis ground
2) Disconnect connectors HM-CN2A and HM-23A.
Short circuit with chassis 4) Turn starting switch ON.
4
ground in wiring harness Resistance value between
HM-CN2 (female) ,
HM-23A (female) – chas-
HM-23A (female)
sis ground
5 Defective VHMS controller 5) Start engine.
Between HM-CN2A and 20 °C Voltage Approx. 0.9 – 1.2 V
20-1016 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-1017

➁
[DGT5KA] (OR VHMS_LED DISPLAYS [n322])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6
(REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in No. 4, 5, 6
Trouble
None DGT5KA None (rear) exhaust temperature sensor system (KA)
Contents of trouble • Signal voltage of less than 0.3V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
• No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function
appears on machine
• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601).
Related information

2) Replace No. 4, 5, 6 (ear) exhaust temperature sensor
Defective No. 4, 5, 6 (ear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (ear) 4) Connect connector.
amp
HM-23B Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Probable cause 3) Connect T-adapter.
and standard value
when normal Disconnection in wiring Resistance Max. 1 Ω
harness and HM-23B (female)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
and HM-23B (female)
Wiring harness between HM-22B (female)
and HM-21B (female)
Wiring harness between HM-22B (female)
and HM-21B (female)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Short circuit with chassis HM-CN1 (female) , HM-
4 HM-CN1 (female) and Min. 1 MΩ
ground in wiring harness 23B (female) – chassis
HM-23B (female)
ground
23B (female) – chassis
HM-23B (female)
ground
20-1018 HD465-7, HD605-7

➁

Probable cause 3) Insert T-adapter.
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
HD465-7, HD605-7 20-1019

➁
[DGT5KB] (OR VHMS_LED DISPLAYS [n321])

SHORT CIRCUIT WITH POWER SOURCE IN NO. 4, 5, 6 (REAR) EXHAUST
TEMPERATURE SENSOR SYSTEM (KB)
Action code Error code Controller code Short circuit with power source in No. 4, 5, 6 (rear) exhaust tem-
Trouble
None DGT5KB None perature sensor system (KB)
Contents of trouble • Signal voltage of more than 4.9V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
• No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function.
appears on machine
Related information

2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor
Defective No. 4, 5, 6 (rear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (rear) 4) Connect connector.
amp
HM-23B Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21B and HM-22B.
Probable cause Short circuit with chassis
and standard value 3 ground in wiring harness Resistance value between
when normal HM-22B (female) ,
HM-22B (female) and Min. 1 MΩ
HM-21B (female) – chas-
HM-21B (female)
sis ground
2) Disconnect connectors HM-CN2A and HM-23B.
Short circuit with chassis 4) Turn starting switch ON.
4
ground in wiring harness Resistance value between
HM-CN2 (female) ,
HM-23B (female) – chas-
HM-23B (female)
sis ground
20-1020 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-1021

➁
TROUBLESHOOTING [DHE5KB]
[DHE5KB] (OR VHMS_LED DISPLAYS [n332])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE
BLOW-BY PRESSURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in engine blow-
Trouble
None DHE5KB None by pressure sensor system (KA)
Contents of trouble • Signal voltage of blow-by pressure sensor has dropped below 0.1V.
Problem that
• Blow-by pressure cannot be monitored with monitoring function.
appears on machine
• Blow-by pressure can be checked with monitoring function (code: 42800).
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 and Voltage 4.5 – 5.5V
Between HM-12 and Voltage 0.3 – 0.7V
2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
2 ness (disconnection, defec- Wiring harness between HM-CN1 (female)
tive contact) , – HM-12 (female)
and HM-12 (female)
Probable cause
and standard value 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
when normal
HM-CN1 (female) , ,
Short circuit with chassis HM-CN1 (female) , – Min. 1 MΩ
3 HM-12 (female) – chas-
ground in wiring harness HM-12 (female)
sis ground
12 (female) - chassis
HM-12 (female)
ground
4 Defective VHMS controller
5) Start engine.
Between HM-CN1 and HM-CN2A Voltage 4.5 – 5.5V
Between HM-CN2A and Voltage 0.3 – 0.7V
20-1022 HD465-7, HD605-7

➁
TROUBLESHOOTING [DHE5KY]
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER

SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)
Action code Error code Controller code Short circuit with power source in engine blow-by pressure sen-
Trouble
None DHE5KY None sor system (KY)
Contents of trouble • Signal voltage of blow-by pressure sensor has risen above 4.7V.
Problem that
• Blow-by pressure cannot be monitored with monitoring function.
appears on machine
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 and Voltage 4.5 – 5.5 V
Between HM-12 and Voltage 0.3 – 0.7 V
Probable cause
and standard value
when normal Short circuit with chassis
ground in wiring harness
HM-CN2A (female) and (female) , HM-12 (female) Max. 1 V
HM-12 (female) – chassis ground
Between HM-CN1 and HM–CN2A Voltage 4.5 – 5.5 V
Between HM-CN2A and Voltage 0.3 – 0.7 V
HD465-7, HD605-7 20-1023

!
TROUBLESHOOTING [DhP4KX]
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Front right): Out of input signal
Trouble
E01 DhP4KX PLM range (KX)
• The voltage of the signal circuit of the suspension pressure sensor (Front right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
• The payload is not indicated and saved correctly.
appears on machine
• The suspension pressure (Front right) signal can be checked with the monitoring function (Code:
Related information 32804).
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z
1 ness (Disconnection or de- (1) and SUFR (female) (C)
fective contact) Wiring harness between HM-CN1 (female) (2)
Resistance Max. 1 z
and SUFR (female) (B)
Wiring harness between HM-CN2B (female)
Resistance Max. 1 z
(9) and SUFR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
Resistance between HM-
CN2B (female) (1), SUFR
Grounding fault in wiring HM-CN2B (female) (1) and Min. 1 M z
2 (female) (C) and chassis
harness SUFR (female) (C)
ground
Resistance between HM-
CN1 (female) (2), SUFR
HM-CN1 (female) (2) and Min. 1 M z
(female) (B) and chassis
Probable cause SUFR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SUFR.
Short circuit with power 4) Turn starting switch ON.
3
Wiring harness between Voltage between HM-CN2B
HM-CN2B (female) (1) and (female) (1), SUFR (female) Max. 1 V
3) Insert connect T-adapter.
Defective suspension pres- 4) Connect connector.
4
sure sensor (Front right) 5) Turn starting switch ON.
Between SUFR (B) and (A) Voltage 20 – 30 V
2) Disconnect connectors HM-CN1 and HM-CN2B.
Defective VHMS & PLM 4) Connect connector.
5
controller 5) Turn starting switch ON.
Between HM-CN1 (2) and HM-CN2B (9) Voltage 20 – 30 V
Between HM-CN2B (1) and (9) Voltage 1.0 – 4.6 V
20-1023-1 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-1023-2

!
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Front left): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Front left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Front left) signal can be checked with the monitoring function (Code:
Related information 32805).

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
1 ness (Disconnection or de- (2) and SUFL (female) (C)
Resistance Max. 1 z
and SUFL (female) (B)
Resistance Max. 1 z
(9) and SUFL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
HM-CN2B (female) (2) and CN2B (female) (2), SUFL
Grounding fault in wiring Min. 1 M z
2 SUFL (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), SUFL (fe-
Min. 1 M z
SUFL (female) (B) male) (B) and chassis
Probable cause ground
and standard value
2) Disconnect connectors HM-CN2B and SUFL.
3
HM-CN2B (female) (2) and (female) (2), SUFL (female) Max. 1 V
4
sure sensor (Front left) 5) Turn starting switch ON.
Between SUFL (B) and (A) Voltage 20 – 30 V
5
20-1023-3 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-1023-4

➄
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Rear right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32806).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 Ω
1 ness (Disconnection or de- (7) and SURR (female) (C)
and SURR (female) (B)
(9) and SURR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
HM-CN2B (female) (7) and CN2B (female) (7), SURR
2 SURR (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (7), SURR
Min. 1 M Ω
SURR (female) (B) (female) (C) and chassis
and standard value
2) Disconnect connectors HM-CN2B and SURR.
3
HM-CN2B (female) (7) and (female) (7), SURR (female) Max. 1 V
SURR (female) (C) (C) and chassis ground
2) Disconnect connector SURR.
4
sure sensor (Rear right) 5) Turn starting switch ON.
Between SURR (B) and (A) Voltage 20 – 30 V
Between SURR (C) and (A) Voltage 1.0 – 4.6 V
5
20-1023-5 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1023-6

➄
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Rear left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32807).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 Ω
1 ness (Disconnection or de- (8) and SURL (female) (C)
and SURL (female) (B)
(9) and SURL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
HM-CN2B (female) (8) and CN2B (female) (8), SURL
2 SURL (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), SURL (fe-
Min. 1 M Ω
SURL (female) (B) male) (B) and chassis
and standard value
2) Disconnect connectors HM-CN2B and SURL.
3
HM-CN2B (female) (8) and (female) (8), SURL (female) Max. 1 V
SURL (female) (C) (C) and chassis ground
2) Disconnect connector SURL.
4
sure sensor (Rear left) 5) Turn starting switch ON.
Between SURL (B) and (A) Voltage 20 – 30 V
Between SURL (C) and (A) Voltage 1.0 – 4.6 V
5
20-1023-7 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1023-8

!
TROUBLESHOOTING [DKH1KX]
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Pitch angle sensor: Out of input signal range (KX)
E01 DKH1KX PLM
Contents of trouble • The voltage of the signal circuit of the pitch angle sensor is below 0.3 V or above 4.9 V.
Problem that
appears on machine
• The pitch angle sensor signal [Angle (rad)] can be checked with the monitoring function (Code: 32901).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and PM3.
1 ness (Disconnection or de- (3) and PM3 (female) (B)
Resistance Max. 1 z
and PM3 (female) (C)
Resistance Max. 1 z
(9) and PM3 (female) (A)
2) Disconnect connectors BRCB and PM3.
HM-CN2B (female) (3) and CN2B (female) (3), PM3 (fe-
Grounding fault in wiring Min. 1 M z
2 PM3 (female) (B) male) (B) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), PM3 (fe-
Min. 1 M z
Probable cause PM3 (female) (C) male) (C) and chassis
and standard value ground
2) Disconnect connectors BRC3B and PM3.
3
HM-CN2B (female) (3) – (female) (3), MP3 (female) Max. 1 V
PM3 (female) (B) (B) and chassis ground
2) Disconnect connectors PM3.
4 Defective pitch angle sensor 4) Turn starting switch ON.
Between PM3 (C) and (A) Voltage 20 – 30 V
Between PM3 (B) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors PM5 and HM-CN2B
5
20-1023-9 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DKH1KX]
HD465-7, HD605-7 20-1023-10

(6)
TROUBLESHOOTING [F@BBZL]
[F@BBZL] (OR VHMS_LED DISPLAYS [n338])

ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)

Trouble Engine blow-by pressure is high: (ZL)
None F@BBZL None
Contents of trouble • Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.
Problem that
appears on machine
Related information
• If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in blow-by
Probable cause 1 Inspect engine and repair if any abnormality is found
pressure
and standard value
when normal Defective orifice inside
2 Inspect orifice inside breather and repair if any abnormality is found
breather
3 Defective VHMS controller If Items 1 and 2 are normal, defective VHMS controlle
20-1024 HD465-7, HD605-7

➁
TROUBLESHOOTING [F@BYNR]
[F@BYNR] (OR VHMS_LED DISPLAYS [n362])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)
None F@BYNR None
• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
750 °C at more than rated output speed and 800 °C at less than max. torque speed)
Problem that
appears on machine
• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600)
Related information
• If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in exhaust
temperature for No. 1, 2, 3
1 Inspect engine and repair if any abnormality is found
(front)
(When system is normal)
and standard value 2) Disconnect connectors HM-CN1 and HM-CN2A.
when normal 3) Insert T-adapter.
HD465-7, HD605-7 20-1025

➁
TROUBLESHOOTING [F@BYNS]
[F@BYNS] (OR VHMS_LED DISPLAYS [n361])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)
None F@BYNS None
• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(front)
20-1026 HD465-7, HD605-7

➁
TROUBLESHOOTING [F@BZNR]
[F@BZNR] (OR VHMS_LED DISPLAYS [n372])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)
None F@BZNR None
• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
HD465-7, HD605-7 20-1027

➁
TROUBLESHOOTING [F@BZNS]
[F@BZNS] (OR VHMS_LED DISPLAYS [n371])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)
None F@BZNS None
• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
Between HM-CN2A and 20° C Voltage Approx. 0.9 – 1.2 V
20-1028 HD465-7, HD605-7

➁
TROUBLESHOOTING VHMS-1
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION

a) Satellite communication data are not transmitted
Action code Error code Controller code Abnormality in satellite data communication
Trouble
None None None a) Satellite communication data are not transmitted
Contents of trouble • Satellite communication data are not transmitted.
Problem that
• Satellite communication data are not transmitted.
appears on machine
Related information
aMove the machine outdoors.

Machine is in tunnel or build- • Not defective.
1
ing
aMove the machine to a place from where you can look out over the
Machine is behind building • Not defective.
2 or mountain and only a part
of heaven is seen from it heavens.
Abnormality in communica- • Check communication antenna. If it is broken or removed, repair or
3
tion antenna replace it.
Entry of foreign matter in
4 communication antenna • Check inside of communication antenna and remove foreign matter.
connector
Abnormality in communica- • Check communication antenna. If it is broken (or disconnected), re-
5
tion antenna cable pair or replace it.
2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A,
and ORB-B.
Wiring harness between ORB-B (female) (1)
and HM-CN4B (female) (4)
Disconnection in wiring har- and HM-CN4B (female) (10) Resistance Max. 1 Ω
Probable cause 6 ness (Disconnection or de-
and standard value fective contact) Resistance Max. 1 Ω
and HM-CN4B (female) (3)
when normal
Wiring harness between ORB-A (female) (7),
(8) and HM-CN1 (female) (6), (7)
Wiring harness between ORB-A (female) (10),
(11) and HM-CN1 (female) (19), (20)
Wiring harness between ORB-A (female) (2)
and HM-CN2 (female) (17)
and ORB-B.
Wiring harness between Resistance between ORB-B
ORB-B (female) (1) and HM- (female) (1), HM-CN4B (fe-
Min. 1M Ω
CN4B (female) (4) male) (4) and chassis
Grounding fault or short cir- ground
7
cuit in wiring harness Wiring harness between Resistance between ORB-B
Min. 1M Ω
ground
Wiring harness between Resistance between ORB-B
Min. 1M Ω
ground
HD465-7, HD605-7 20-1029

➄

Wiring harness between Resistance between ORB-A
ORB-A (female) (7), (8) and (female) (7), (8)HM-CN1 (fe-
Min. 1M Ω
HM-CN1 (female) (6), (7) male) (6), (7) and chassis
ground
ORB-A (female) (10), (11) (female) (10), (11), HM-CN1
Min. 1M Ω
and HM-CN1 (female) (19), (female) (19), (20) and chas-
(20) sis ground
ORB-A (female) (2) and HM- (female) (2), HM-CN2A (fe-
Min. 1M Ω
CN2A (female) (17) male) (17) and chassis
ground
Between wiring harness be- Resistance between wiring
tween ORB-B (female) (1) harness between ORB-B
and HM-CN4B (female) (4) (female) (1) and HM-CN4B
and wiring harness between (female) (4) and wiring har- Min. 1M Ω
ORB-B (female) (2) and HM- ness between ORB-B (fe-
CN4B (female) (10) male) (2) and HM-CN4B
(female) (10)
Grounding fault or short cir- ORB-B (female) (3) and HM- ness between ORB-B (fe-
7
cuit in wiring harness CN4B (female) (3) male) (3) and HM-CN4B
Probable cause (female) (3)
and standard value
when normal
ORB-B (female) (3) and HM- ness between ORB-B (fe-
CN4B (female) (3) male) (3) and HM-CN4B
(female) (3)
tween ORB-A (female) (7), harness between ORB-A
(8) and HM-CN1 (female) (female) (7), (8) and HM-
(6), (7) and wiring harness CN1 (female) (6), (7) and
Min. 1M Ω
between ORB-A (female) wiring harness between
(10), (11) and HM-CN1 (fe- ORB-A (female) (10), (11)
male) (19), (20) and HM-CN1 (female) (19),
(20)
tween ORB-A (female) (2) harness between ORB-A
and HM-CN2A (female) (17) (female) (2) and HM-CN2A
ORB-A (female) (10), (11) ness between ORB-A (fe-
and HM-CN1 (female) (19), male) (10), (11) and HM-
(20) CN1 (female) (19), (20)
Short circuit with power and ORB-B.
8
source in wiring harness 3) Insert connect T-adapter.
20-1030 HD465-7, HD605-7

➄

Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (1) and HM- male) (1), HM-CN4B (fe- Max. 1 V
CN4B (female) (4) male) (4) and chassis ground
Wiring harness between Voltage between ORB-B
Max. 1 V
ground
8 Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (3) and HM- male) (3), HM-CN4B (fe-
Max. 1 V
CN4B (female) (3) and chas- male) (3) and chassis ground
sis ground
Wiring harness between Voltage between ORB-A (fe-
ORB-A (female) (2) and HM- male) (2), HM-CN2A (fe-
Min. 1 M Ω
CN2A (female) (17) male) (17) and chassis
and standard value
when normal 1) Turn starting switch ON.
About 3 minutes after the VHMS controller is turned ON, judge by
the state of the decimal point of the VHMS controller LED (7 seg-
ments on the right side).
• VHMS controller cannot communicate with
Decimal point goes off ORBCOMM controller (Abnormality in ORB-
COMM controller).
Defective ORBCOMM con- • Communication with VHMS is normal.
9
troller Decimal point lights up • ORBCOMM controller does not have data to
transmit.
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
quickly
and has captured satellite (is transmitting).
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
slowly
but has not captured satellite.
HD465-7, HD605-7 20-1031

➄
b) Abnormality in downloading into PC or setting of PC
Action code Error code Controller code Abnormality in satellite data communication
Trouble
None None None b) Abnormality in downloading into PC or setting of PC
Contents of trouble • PC cannot download or cannot be set.
Problem that
• PC cannot download or cannot be set.
appears on machine
Related information

2) Disconnect connectors HM-CN4A and VHMS.
ness (Disconnection or de- Wiring harness between HM-CN4A (female)
aWiring harness for down-

1 fective contact) (9) and VHMS (female) (B)
loading in cab Resistance Max. 1 Ω
(10) and VHMS (female) (C)
(11) and VHMS (female) (D)
2) Disconnect connectors HM-CN4A and VHMS.
HM-CN4A (female) (9) and CN4A (female) (9), VHMS
Min. 1M Ω
VHMS (female) (B) (female) (B) and chassis
ground
Min. 1M Ω
VHMS (female) (C) (female) (C) and chassis
Probable cause
ground
and standard value
when normal Wiring harness between Resistance between HM-
Min. 1M Ω
VHMS (female) (D) (female) (D) and chassis
ground
Grounding fault or short cir-
aWiring harness for down- tween HM-CN4A (female)

cuit in wiring harness Between wiring harness be- Resistance between wiring
2 harness between HM-CN4A
loading inside cab (9) and VHMS (female) (B) (female) (9) and VHMS (fe-
Min. 1M Ω
and wiring harness between male) (B) and wiring harness
HM-CN4A (female) (10) and between HM-CN4A (female)
VHMS (female) (C) (10) and VHMS (female) (C)
tween HM-CN4A (female) harness between HM-CN4A
(9) and VHMS (female) (B) (female) (9) and VHMS (fe-
Min. 1M Ω
and wiring harness between male) (B) and wiring harness
HM-CN4A (female) (11) and between HM-CN4A (female)
VHMS (female) (D) (11) and VHMS (female) (D)
Between wiring harness be- Resistance between HM-
tween HM-CN4A (female) CN4A (female) (10) and
(10) and VHMS (female) (C) VHMS (female) (C) and wir-
Min. 1M Ω
and wiring harness between ing harness between HM-
HM-CN4A (female) (11) and CN4A (female) (11) and
VHMS (female) (D) VHMS (female) (D)
20-1032 HD465-7, HD605-7

➄

2) Disconnect connectors VHMS and VDL.
ness (Disconnection or de- Wiring harness between VHMS (male) (B) and
aWiring harness for down-

3 fective contact) VDL (female) (B)
Wiring harness between VHMS (male) (C)
loading inside cab Resistance Max. 1 Ω
and VDL (female) (C)
Wiring harness between VHMS (male) (D) and
VDL (female) (D)
2) Disconnect connectors VHMS and VDL.
Wiring harness between Resistance between wiring
VHMS (male) (B) and VDL harness between VHMS
Min. 1M Ω
(female) (B) (male) (B) and VDL (female)
(B) and chassis ground
Wiring harness between Resistance between wiring
VHMS (male) (C) and VDL harness between VHMS
Min. 1M Ω
(female) (C) (male) (C) and VDL (female)
Probable cause
(C) and chassis ground
and standard value
when normal Wiring harness between Resistance between wiring
VHMS (male) (D) and VDL harness between VHMS
Min. 1M Ω
(female) (D) (male) (D) and VDL (female)
(D) and chassis ground
Grounding fault or short cir-
aWiring harness for down- tween VHMS (male) (B) and

cuit in wiring harness Between wiring harness be- Resistance between wiring
4 harness between VHMS
loading outside cab VDL (female) (B) and wiring (male) (B) and VDL (female)
Min. 1M Ω
harness between VHMS (B) and wiring harness be-
(male) (C) and VDL (female) tween VHMS (male) (C) and
(C) VDL (female) (C)
tween VHMS (male) (B) and harness between VHMS
VDL (female) (B) and wiring (male) (B) and VDL (female)
Min. 1M Ω
harness between VHMS (fe- (B) and wiring harness be-
male) (D) and VDL (male) tween VHMS (male) (D) and
(D) VDL (female) (D)
tween VHMS (male) (C) and harness between VHMS
VDL (female) (C) and wiring (male) (C) and VDL (female)
Min. 1M Ω
harness between VHMS (C) and wiring harness be-
(male) (D) and VDL (female) tween VHMS (male) (D) and
(D) VDL (female) (D)
HD465-7, HD605-7 20-1033

➄
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER

(DATA ARE NOT SAVED)
Action code Error code Controller code Abnormality in saving data in VHMS controller
a LED of VHMS counts up and operates normally

Trouble (Data are not saved)
None None None
aPower is kept turned off.

• Data are not saved in the VHMS controller.
Contents of trouble

Problem that
• None in particular.
appears on machine
• If fuse BT-2 (29) is broken, check the wiring harness between fuse and HM-CN1 (6), (7) for grounding
Related information
fault.

2) Disconnect connector HM-CN1 and fuse terminal BT-2 (29).
Wiring harness between HM-CN1 (female) (6),
Probable cause Resistance Max. 1 Ω
(7) and fuse terminal BT-2 (29)
and standard value Disconnection in wiring har-
1 ness (Disconnection or de- 1) After the starting switch is turned to the OFF position, the LED of
when normal
fective contact) the VHMS displays SH (Processing time of memory), and then
the all operation is finished (the power for the VHMS is turned
OFF), if the all system is normal.
2) If the power for the VHMS is turned OFF immediately after the
starting switch is turned to the OFF position, the power is not ap-
plied constantly.
20-1034 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1035

➄
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW

(WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT
IS NORMAL)
Action code Error code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring instrument
None None None is normal)
Contents of trouble • The engine blow-by pressure indicated by the monitor is low.
Problem that • The engine blow-by pressure indicated by the monitor is low.
appears on machine (The blow-by pressure measured with a measuring instrument is normal.)
• The blow-by pressure can be checked with the monitoring function (Code: 42800).
Related information
• If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
Probable cause Cause Standard value in normal state/Remarks on troubleshooting

and standard value 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal.
when normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.
20-1036 HD465-7, HD605-7

➄
TROUBLESHOOTING OF ASR
CONTROLLER SYSTEM
(ASR MODE)
Electrical system diagram related ASR control ........................................................................................ 20-1052

Information in troubleshooting table...................................................................................................... 20-1053
Trouble code table ................................................................................................................................ 20-1054
[DDDAKA] ASR system switch system: Disconnection (KA).............................................................. 20-1055
[DDDAKB] ASR system switch system: Short circuit (KB) ................................................................. 20-1056
[DK30KX] Steering angle sensor: Out of input signal range (KX) .................................................... 20-1057
[DLF8KA] Wheel speed sensor (RR): Disconnection (KA) ............................................................... 20-1059
[DLF8LC] Wheel speed sensor (RR): See separate list (LC) ...................................................... 20-1060
[DLF9KA] Wheel speed sensor (RL): Disconnection (KA) ................................................................ 20-1061
[DLF9LC] Wheel speed sensor (RL): See separate list (LC) ........................................................ 20-1062
[dLT3LC] Transmission output shaft speed sensor: See separate list (LC) ................................ 20-1063
[DWNBK4] Shut-off solenoid valve: Uncontrollable (K4) .................................................................... 20-1065
[DWNBKA] Shut-off solenoid valve: Disconnection (KA) .................................................................... 20-1067
[DWNBKB] Shut-off solenoid valve: Short circuit (KB) ....................................................................... 20-1068
[DWNBKY] Shut-off solenoid valve: Short circuit with power source (KY) .......................................... 20-1069
[DWNBMA] Shut-off solenoid valve: Malfunction (MA) ........................................................................ 20-1070
[DX17K4] ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4) ............ 20-1071
[DX17KA] ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA) ............ 20-1073
[DX17KB] ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)................ 20-1074
[DX17KY] ASR proportional solenoid pressure reducing valve (Right): Short circuit with
power source (KY)............................................................................................................ 20-1075
[DX17MA] ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)................ 20-1076
[DX18K4] ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4) .............. 20-1077
[DX18KA] ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA) .............. 20-1079
[DX18KB] ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB) .................. 20-1080
[DX18KY] ASR proportional solenoid pressure reducing valve (Left): Short circuit with
power source (KY)............................................................................................................ 20-1081
[DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082
HD465-7, HD605-7 20-1051

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
20-1052 HD465-7, HD605-7

➄

panel panel panel
Contents of trouble Condition at the time when the monitor panel or controller detects the trouble
The action taken by the monitor panel or controller to protect the system or devices when the monitor-
panel or controller detects the trouble
Problem that The problem that appears on the machine as a result of the action taken by the monitor panel or controller
appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting

1
• Disconnection
• Grounding fault
• Short circuit
Possible causes 3 Possible causes of trouble <Precautions for troubleshooting>

and standard value (Given numbers are refer- (1) Method of indicating connector No. and handling of T-
in normal state ence numbers, which do not adapter
indicate priority) Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
4
side.
• If connector No. has marks of "male" and "female", disconnect
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
5 • Connect positive (+) lead to pin No. or harness entered on front
side.
side.
HD465-7, HD605-7 20-1053

➄
This a circuit diagram of the part related to the failure.

• Connector No.: Shows the "Type – Number of pin" and " Color".
• Arrow (⇔): Roughly shows the location on the machine.
TROUBLE CODE TABLE

a Regarding trouble code provided with instruction "Refer to table", check it against table below.


KY source LC rpm signals in two systems are inconsistent.

KZ cuit LD Switch is pressed for usually unthinkable long time.
MA Malfunction LH Fill signal is OFF when command current to ECMV is ON.

MB Performance reduction
MW Sliding
NS Overheat
20-1054 HD465-7, HD605-7

➄
TROUBLESHOOTING [DDDAKA]
[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Trouble ASR system switch system: Short circuit (KA)
E01 DDDAKA BK
Contents of trouble • The ASR system switch ON input and system switch OFF input are turned OFF.
Action of controller • Resets the ASR control.
Problem that • The machine is not affected badly.
appears on machine • The ASR system cannot be controlled.
Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring Wiring harness between DPC2B (female) (3)
harness and ASR (female) (3)
1
(Disconnection or defective 1) Turn starting switch OFF.
contact) 2) Disconnect connectors ASR and DPC2B.
Wiring harness between DPC2B (female) (9)
and ASR (female) (3)
2) Replace ASR system switch with normal one.
Possible causes
and standard value 3) Turn starting switch ON.
Defective ASR system
in normal state 2 System switch is nor-
switch When ASR system switch is Yes
mal
replaced with normal one, does
condition become normal? System switch is defec-
No
tive
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON Voltage 20 – 30 V
and chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
and chassis ground ASR system switch OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1055

➄
TROUBLESHOOTING [DDDAKB]
[DDDAKB] ASR SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Trouble ASR system switch system: Short circuit (KB)
E01 DDDAKB BK
Contents of trouble • The ASR system switch ON input and system switch OFF input are turned ON.
Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
Short circuit with power Wiring harness between Voltage between DPC2B
1 DPC2B (female) (3) and (female) (3), ASR (female) Max. 1 V
ASR (female) (3) (3) and chassis ground
Wiring harness between Voltage between DPC2B
DPC2B (female) (9) and (female) (9), ASR (female) Max. 1 V
ASR (female) (2) (2) and chassis ground
2) Replace ASR system switch with normal one.
Possible causes
Defective ASR system 3) Turn starting switch ON.
and standard value
in normal state 2 switch System switch is nor-
When ASR system switch is re- Yes
mal
placed with normal one, does con-
dition become normal? System switch is defec-
No
tive
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON Voltage 20 – 30 V
and chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
and chassis ground ASR system switch OFF Voltage 20 – 30 V
20-1056 HD465-7, HD605-7

➄
[DK30KX] STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Steering angle sensor: Out of input signal range (KX)
E01 DK30KX BK
Contents of trouble • The voltage of the signal circuit of the steering angle sensor is below 0.5 V or above 4.7 V.
Action of controller • Controls the ASR by setting the steering angle (turning angle) to 20 degrees.
Problem that
• The machine is not affected badly.
appears on machine
Related information • The steering angle can be checked with the monitoring function (Code: 35400).

2) Disconnect connectors BRC2, BRC3A, and ASR1.
Disconnection in wiring Wiring harness between BRC2 (female) (16)
1 and ASR1 (female) (3)
and ASR1 (female) (2)
Wiring harness between Resistance between BRC2
Grounding fault in wiring BRC2 (female) (16) and (female) (16), ASR 1 (female) Min. 1 MΩ
2
harness ASR1 (female) (3) (3) and chassis ground
BRC3A (female) (7) and (female) (7), ASR1 (female) Min. 1 MΩ
ASR1 (female) (2) (2) and chassis ground
Possible causes
and standard value
in normal state
Short circuit with power Voltage between BRC2
3 Wiring harness between
source in wiring harness BRC2 (female) (16) and (female) (16), ASR1 (female) Max. 1 V
BRC3A (female) (7) and (female) (7), ASR1 (female) Max. 1 V
2) Disconnect connector RTL.
Defective steering angle 4) Connect connector.
4
sensor 5) Turn starting switch ON.
Between ASR (3) and (1) Voltage 4.6 – 5.4 V
Between ASR (2) and (1) Voltage 2–3V
2) Disconnect connectors BRC2 and RTL.
5 Defective retarder controller
Between BRC1 (16) and BRC3A (16) Voltage 4.6 – 5.4 V
Between BRC3A (7) and (16) Voltage 2–3V
HD465-7, HD605-7 20-1057

➄
20-1058 HD465-7, HD605-7

➄
[DLF8KA] WHEEL SPEED SENSOR (RR): DISCONNECTION (KA)

Trouble Wheel speed sensor (RR): Disconnection (KA)
E01 DLF8KA BK
Contents of trouble • The signal circuit of the wheel speed sensor (RR) is disconnected and signals are not input.
Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
Defective wheel speed
1
sensor (RR) Between WSRR (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRR (male) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRR.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
2 Wiring harness between BRC3A (female) (3)
(Disconnection or defective and WSRR (female) (1) Resistance Max. 1 Ω
contact)
and WSRR (female) (2)
3 Defective retarder controller 3) Connect T-adapter.
Between BRC3A (female) (3) and (14) Resistance 950 – 1,450 Ω
HD465-7, HD605-7 20-1059

➄
[DLF8LC] WHEEL SPEED SENSOR (RR): SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RR): See separate list (LC)
E01 DLF8LC BK
• The wheel speed (RR) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor.
Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
1
sensor (RR) Between WSRR (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRR (male) (1), (2) and chassis
ground
2
harness Wiring harness between Resistance between BRC3A
Possible causes
and standard value BRC3A (female) (3) and (female) (3), WSRR (female) Min. 1 MΩ
in normal state WSRR (female) (1) (1) and chassis ground
harness
BRC3A (female) (3) and male) (3), WSRR (female) (1) Max. 1 V
WSRR (female) (1) and chassis ground
20-1060 HD465-7, HD605-7

➄
[DLF9KA] WHEEL SPEED SENSOR (RL): DISCONNECTION (KA)

Trouble Wheel speed sensor (RL): Disconnection (KA)
E01 DLF9KA BK
Contents of trouble • The signal circuit of the wheel speed sensor (RL) is disconnected and signals are not input.
Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
Defective wheel speed sen- 3) Connect T-adapter.
1
sor (RL) Between WSRL (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRL (male) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRL.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
2 Wiring harness between BRC3A (female) (2)
and WSRL (female) (1)
contact)
and WSRL (female) (2)
HD465-7, HD605-7 20-1061

➄
[DLF9LC] WHEEL SPEED SENSOR (RL): SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RL): See separate list (LC)
E01 DLF9LC BK
• The wheel speed (RL) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RR) speed sensor signal is different from the signal speed of the wheel (RL) speed sensor.
Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
1
sensor (RL) Between WSRL (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRL (male) (1), (2) and chassis
ground
2
harness Wiring harness between Resistance between BRC3A
Possible causes
and standard value BRC3A (female) (3) and (female) (3), WSRL (female) Min. 1 MΩ
in normal state WSRL (female) (1) (1) and chassis ground
harness
BRC3A (female) (3) and (female) (3), WSRL (female) Max. 1 V
WSRL (female) (1) (1) and chassis ground
20-1062 HD465-7, HD605-7

➄
TROUBLESHOOTING [dLT3LC]
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:

SEE SEPARATE LIST (LC)
Action code Error code Controller code Transmission output shaft speed sensor: See separate list (LC)
Trouble
E01 dLT3LC BK (ASR is set and ASR system switch is turned ON)
• The travel speed calculated from the transmission output shaft speed sensor signal, wheel (RR) speed
Contents of trouble sensor signal, and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR)
speed sensor and wheel (RL) speed sensor.
• The transmission output shaft speed can be checked with the monitoring function (Code: 31400).
Related information
The wheel speed can be checked with the monitoring function (Code: 39700, 39701).

Defective transmission
1
output shaft speed sensor Between CN5 (male) (1) and (2) Resistance 500 – 1,000 Ω
Between CN5 (male) (1), (2) and chassis
ground
2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5.
Grounding fault in wiring har-
2 Wiring harness between Resistance between BRC3A
ness
ATC3A (female) (3), BRC3A (female) (13), ATC3A (female)
Min. 1 MΩ
Possible causes (female) (13), PM5 (female) (3), PM5 (female) (7), CN5 (fe-
and standard value (7), and CN5 (female) (1) male) (1) and chassis ground
in normal state
2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5.
3
source in wiring harness Voltage between ATC3A
Wiring harness between (female) (3), BRC3A (female)
ATC3A (female) (3), BRC3A
(13), PM5 (female) (7), CN5 Max. 1 V
(female) (13), PM5 (female)
(7), and CN5 (female) (1) (female) (1) and chassis
ground
Defective transmission con- 2) Disconnect connector BRC3A.
troller
HD465-7, HD605-7 20-1063

➄
TROUBLESHOOTING [dLT3LC]
20-1064 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBK4]
[DWNBK4] SHUT-OFF SOLENOID VALVE: UNCONTROLLABLE (K4)

Trouble Shut-off solenoid valve: Uncontrollable (K4)
E01 DWNBK4 BK
Contents of trouble • The shut-off solenoid valve does not return (does not move) or the pressure switch system is defective.
Related information

Defective shut-off solenoid • Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2) Disconnect connector ASR7.
Defective shut-off solenoid 4) Connect connector.
2
valve oil pressure switch 5) Turn starting switch ON.
Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 Ω
and (2) Oil pressure OFF Resistance Min. 1 MΩ
2) Disconnect connectors BRC5B and ASR7.
and standard value Wiring harness between Resistance between BRC5B
in normal state BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 Ω
BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 V
2) Disconnect connectors BRC5B and BRC2.
Between BRC5B (8) and Oil pressure ON Voltage Max. 1 V
BRC2 (21) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1065

➄
TROUBLESHOOTING [DWNBK4]
20-1066 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBKA]
[DWNBKA] SHUT-OFF SOLENOID VALVE: DISCONNECTION (KA)

Trouble Shut-off solenoid valve: Disconnection (KA)
E01 DWNBKA BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, any current does not flow.
Related information

1
valve 5) Turn starting switch ON.
Between ASR2 (female) (1) and (2) Resistance 10 – 30 Ω
Between ASR2 (1), (2) and chassis ground Resistance Min. 1 MΩ
Possible causes
and standard value
2) Disconnect connectors BRC2 and ASR2.
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (2)
defective contact) and ASR2 (female) (1)
HD465-7, HD605-7 20-1067

➄
TROUBLESHOOTING [DWNBKB]
[DWNBKB] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT (KB)

Trouble Shut-off solenoid valve: Short circuit (KB)
E01 DWNBKB BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, too much current flows.
Related information

1
and standard value Wiring harness between Resistance between BRC2
in normal state BRC2 (female) (2) and ASR2 (female) (2), ASR2 (female) Max. 1 Ω
Grounding fault or short (female) (1) (1) and chassis ground
2
circuit in wiring harness Between wiring harness be-
tween BRC2 (female) (2) Resistance between BRC2
and ASR2 (female) (1) and (female) (2), ASR2 (female)
Max. 1 Ω
wiring harness between (1) and BRC2 (female) (13),
BRC2 (female) (13) and ASR2 (female) (2)
ASR2 (female) (2)
20-1068 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBKY]
[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE (KY)

Trouble Shut-off solenoid valve: Short circuit with power source (KY)
E01 DWNBKY BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned OFF, a current flows.
Related information

1
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors BRC2 and ASR2.
Short circuit with power 4) Connect connector
Wiring harness between Voltage between BRC2
BRC2 (female) (2) and ASR2 (female) (2), ASR2 (female) Max. 1 V
(female) (1) (1) and chassis ground
HD465-7, HD605-7 20-1069

➄
TROUBLESHOOTING [DWNBMA]
[DWNBMA] SHUT-OFF SOLENOID VALVE: MALFUNCTION (MA)

Trouble Shut-off solenoid valve: Malfunction (MA)
E01 DWNBMA BK
• The shut-off solenoid valve does not operate (does not move) or the pressure switch system is
Contents of trouble
defective.
Related information

Defective shut-off solenoid • Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2
valve oil pressure switch 5) Turn starting switch ON.
Possible causes
in normal state 2) Disconnect connectors BRC5B and ASR7.
3
harness Wiring harness between Resistance between BRC5B
BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 Ω
20-1070 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX17K4]
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

UNCONTROLLABLE (K4)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Right):
Trouble
E01 DX17K4 BK Uncontrollable (K4)
• The ASR proportional solenoid pressure reducing valve (Right) does not return (does not move) or the
Contents of trouble
pressure switch system is defective.
Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
Defective ASR proportional 3) Insert connect T-adapter.
solenoid pressure reducing 4) Connect connector.
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Wiring harness between Resistance between BRC5B
HD465-7, HD605-7 20-1071

➄
20-1072 HD465-7, HD605-7

➄
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

DISCONNECTION (KA)
Trouble
• When the output to the ASR proportional solenoid pressure reducing valve (Right) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

Defective ASR proportional
1 solenoid pressure reducing 4) Connect connector.
valve (Right)
Possible causes
and standard value
in normal state Disconnection in wiring 3) Connect T-adapter.
harness
(Disconnection or defective and ASR3 (female) (1) Resistance Max. 1 Ω
contact)
HD465-7, HD605-7 20-1073

➄
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT (KB)
Trouble
E01 DX17KB BK Short circuit (KB)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Right)
Possible causes
and standard value
in normal state
Grounding fault or short
2 BRC2 (female) (9) and (female) (9), ASR3 (female) Min. 1 MΩ
circuit in wiring harness
Between wiring harness between BRC2 (female) (9) and
ASR3 (female) (1) and wiring harness between BRC2 Min. 1 MΩ
(female) (19) and ASR3 (female) (2)
20-1074 HD465-7, HD605-7

➄
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT WITH POWER SOURCE (KY)
Trouble
E01 DX17KY BK Short circuit with power source (KY)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Right)
Possible causes
and standard value
4) Connect connector
in normal state
2 Wiring harness between Voltage between BRC2
(female) (19) and ASR (female) (2)
HD465-7, HD605-7 20-1075

➄
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

MALFUNCTION (MA)
Trouble
• The ASR proportional solenoid pressure reducing valve (Right) does not operate (does not move) or
Contents of trouble
the pressure switch system is defective.
Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1076 HD465-7, HD605-7

➄
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

UNCONTROLLABLE (K4)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left):
Trouble
E01 DX18K4 BK Uncontrollable (K4)
• The ASR proportional solenoid pressure reducing valve (Left) does not return (does not move) or the
Contents of trouble
Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

• Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
HD465-7, HD605-7 20-1077

➄
20-1078 HD465-7, HD605-7

➄
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

DISCONNECTION (KA)
Trouble
• When the output to the ASR proportional solenoid pressure reducing valve (Left) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

valve (Left)
Possible causes
and standard value
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (8)
defective contact) and ASR4 (female) (1)
HD465-7, HD605-7 20-1079

➄
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT (KB)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KB BK circuit (KB)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Left)
Possible causes 2) Disconnect connectors BRC2 and ASR4.
and standard value 3) Connect T-adapter.
in normal state
Grounding fault or short
2 BRC2 (female) (8) and (female) (8), ASR4 (female) Min. 1 MΩ
circuit in wiring harness ASR4 (female) (1) (1) and chassis ground
(female) (18) and ASR4 (female) (2)
20-1080 HD465-7, HD605-7

➄
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT WITH POWER SOURCE (KY)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KY BK circuit with power source (KY)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Left)
Possible causes 3) Insert connect T-adapter.
and standard value 4) Connect connector
in normal state 5) Turn starting switch ON.
2 Wiring harness between Voltage between BRC2
(female) (18) and ASR (female) (2)
HD465-7, HD605-7 20-1081

➄
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

MALFUNCTION (MA)
Trouble
• The ASR proportional solenoid pressure reducing valve (Left) does not operate (does not move) or the
Contents of trouble
Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

• Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1082 HD465-7, HD605-7

➄
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEMS (H MODE)
H-1 Machine does not start ....................................................................................................................20-1102

H-2 Machine does not travel smoothly (machine jerks) .........................................................................20-1104
H-3 Lock-up clutch cannot be disengaged (engine stalls) .....................................................................20-1104
H-4 Excessive shock when starting or shifting.......................................................................................20-1105
H-5 Transmission does not shift up........................................................................................................20-1105
a. Does not shift up ........................................................................................................................20-1105
b. Does not shift up ........................................................................................................................20-1105
H-6 Machine lacks power or speed when traveling................................................................................20-1106
a. Abnormality at all speed ranges.................................................................................................20-1106
b. Torque converter lock-up does not engage................................................................................20-1107
c. Abnormality at specific speed ranges ........................................................................................20-1108
H-7 Time lag is excessive when starting or shifting gear .......................................................................20-1110
H-8 Torque converter oil temperature is high .........................................................................................20-1112
H-9 Torque converter oil pressure is low................................................................................................20-1113
H-10 Front brake is ineffective, or effective only on one side ..................................................................20-1114
H-11 Rear brake is ineffective, or effective only on one side ...................................................................20-1115
H-12 Steering wheel is heavy ..................................................................................................................20-1116
H-13 Steering wheel does not work .........................................................................................................20-1117
H-14 Steering wheel vibrates ...................................................................................................................20-1117
H-15 Hoist cylinder lacks lifting force (lifting speed) ...............................................................................20-1118
H-16 Hoist cylinder does not work ...........................................................................................................20-1119
H-17 Excessive hydraulic drift of dump body ...........................................................................................20-1120
HD465-7, HD605-7 20-1101

!
TROUBLESHOOTING H-1
H-1 Machine does not start
Ask the operator the following questions

• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal noise?
Yes = Broken part
Checks before troubleshooting

• Is the oil level in the transmission case cor-
rect?
• Is the torque converter, transmission input
shaft broken? (Check with the transmission
input shaft speed sensor.)
• Is the drive shaft broken?
Drop in set pressure of main relief valve (torque converter valve)

• Is there any dragging of the brakes?
• Is any failure code related power trains dis-
played?
Defective transmission clutch seal ring, groove
Defective speed clutch (defective oil tightness)
Defective shaft seal ring in speed clutch circuit
Defective actuation of ECMV solenoid valve

Causes
Pump does not drive (defective PTO)

Air sucked in at suction side of pump
Defective operation of ECMV valve
Damage inside torque converter
Defective speed sensor function

Damage inside transmission
Seized transmission clutch
Clogged strainer
Defective pump
a b c d e f g h i j k l m n
Remedy
No. C " " " " " " " " "
" "
Problems
1 Abnormal noise comes from between pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 Machine does not start when torque converter oil temperature

rises
5 Low at every speed range
6 Set pressure of Becomes lower at certain speed range

transmission is low
7 Indicator is unstable and fluctuates
excessively
8 When pressure pickup plug is removed and engine is cranked,

no oil comes out
9 Modulation pressure is abnormal
10 Hydraulic pressure at pump outlet port is low
20-1102 HD465-7, HD605-7

(7)
TROUBLESHOOTING H-1
Clutch combination table
Clutch
No.
H L 4th 3rd 2nd 1st R
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1103

!
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)
• There is hunting.
• Look-up lamp flashes.
Causes Remedy
• Drop in main relief pressure 

 A. See H-6
• Worn clutch seal ring 
H-3 Lock-up clutch cannot be disengaged (engine stalls)

• Is the oil level in the transmission case correct?
• Is any failure code related power trains displayed?
Defective actuation of lock-up ECMV solenoid valve
Defective actuation of lock-up ECMV valve

Causes
Seized lock-up clutch
a b c
Remedy
C
.
No. " " "
Problems
1 Lock-up pressure does not become "0"
2 Lock-up clutch is not disengaged even when lock-up

pressure is "0"
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid valve is normal
20-1104 HD465-7, HD605-7

(7)
H-4 Excessive shock when starting or shifting
Judgement standard
There is some shock, but it is difficult to judge if the shock is excessive or not, so judge that it is excessive in the
following cases.
• It is clear that the shock has suddenly become excessive.
• The shock is excessive compared with other machines of the same class.
Cause
• Defective operation because of dirt caught in the ECMV pressure control valve spool and pressure detector
valve spool, or defective operation of the ECMV proportional solenoid.
H-5 Transmission does not shift up
a. Does not shift up

# Shifts up on downhill slopes.
Causes Remedy
Slipping or damage of torque converter lock-up clutch ×
# The above is the most probable cause, but for details, see "Torque converter lock-up does not engage".
b. Does not shift up

Causes Remedy
Defective operation of ECMV for clutch which does not shift up C ×

Defective piston seal ring, defective groove for clutch which does not shift up ×
Drop in main relief pressure A C ×
Clutch combination table
Clutch
No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1105

(7)
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling
a. Abnormality at all speed ranges

• Is the oil level in the transmission case cor-
rect?
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
• Is there any external oil leakage from the
piping or valve joints?
Defective operation of torque converter relief valve, deteriorated spring

• Is there any dragging of the parking brake,
Drop in set pressure of main relief valve (torque converter valve)

service brake, or retarder?
• Is any failure code related power trains dis-
Cooler, piping beyond torque converter outlet port damaged

played?
Damage inside torque converter (turbine rivet broken)

Checking for abnormalities
• Engine high idring speed
• Torque converter stall speed
Torque converter lock-up does not engage

• Machine travel speed Causes
• Transmission clutch pressure
Defective torque converter freewheel

• Torque converter lock-up pressure
Drop in performance of engine

• Main relief pressure
Crogged strainer
Defective pump
a b c d e f g h i j k
Remedy A
C " " A "
No. "
" " "
Problems See b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
2 Torque converter stall speed is high
3 Torque converter stall speed is low

Low at every speed range
4
(Item 2 abnormal)
Set pressure of Indicator is unstable and fluctuates
5
transmission is low excessively
Low after entering torque converter See TORQUE CONVERTER LOCK-UP DOES
6
lock-up NOT ENGAGE.
Hydraulic pressure at torque converter inlet port is low
7
(Items 4 – 6 normal)
Hydraulic pressure at torque converter outlet port is low
8
(Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of
9
transmission case
10 Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops
20-1106 HD465-7, HD605-7

!
TROUBLESHOOTING H-6
b. Torque converter lock-up does not engage

Yes = Internal seizure, damage
• When this happened, was there any abnormal noise?
Yes = Broken part

• Is there any external oil leakage ?
• Is electricity flowing to the lock-up solenoid?
(Use a checker)

• Main relief pressure
• Lock-up oil pressure
Defective operation of lock-up ECMV solenoid valve spool

• Main travel speed
Defective operation of lock-up ECMV valve spool

Drop in set pressure of main relief valve
Causes
Worn lock-up clutch piston seal ring
Cracked lock-up clutch case

Defective lock-up solenoid
Worn lock-up clutch disc
a b c d e f g
Remedy
No. " " "
" " " "
Problems
1 Main relief pressure is low
2 With Item 1 normal, lock-up pressure is low or "0"
3 Solenoid is normal in Item 2 (proper continuity, no short circuit)
4 Solenoid is defective in Item 2 (no continuity, there is short circuit)
5 With Items 1 – 4 normal, lock-up pressure is low
6 Oil pressure is normal in Item 5
7 Lock-up pressure is low and main pressure is also low
8 Lock-up takes time to engage
HD465-7, HD605-7 20-1107

(7)
TROUBLESHOOTING H-6
c. Abnormality at specific speed ranges

• Is the oil level in the transmission case correct? Clutch combination table
• Is there any dragging of the parking brake, ser-
vice brake, or retarder? Clutch
No.
• Is any failure code related power trains dis- H L 4th 3rd 2nd 1st R
played? (Rotat- (Rotat-
Speed ing) ing)
range
• Machine travel speed R
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
(1) F1 is normal, but F2 is defective
1
(2) Returns to normal when replaced with any ECMV except 2nd.
(1) F2 is normal, but F1 is defective or only F1 is defective

2
(2) Returns to normal when replaced with any ECMV except 1st.
(1) F1 and F2 are normal, but F3 is defective

3
(2) Returns to normal when replaced with any ECMV except H.
(1) F1, F2 and F3 are normal, but F4 is defective

4
(2) Returns to normal when replaced with any ECMV except 3rd.
(1) F1 – F5 are normal, but F6 is defective

5
(2) Returns to normal when replaced with any ECMV except 4th.
(1) F3, F5, and F7 are normal, but others are defective
6
(2) Returns to normal when replaced with any ECMV except L.
(1) Only R is defective

7
(2) Returns to normal when replaced with any ECMV except R.
# Remove all the mud and dirt from around the ECMV, and clean it before replacing.
# After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
ECMV mounting bolt : 8.0 – 10.0 Nm {0.8 – 1.0 kgm}
20-1108 HD465-7, HD605-7

(7)
Causes
"
H clutch disc worn or seized, seal ring worn
"
L clutch disc worn or seized, seal ring worn
"
4th clutch disc worn or seized, seal ring worn
HD465-7, HD605-7
d
"
3rd clutch disc worn or seized, seal ring worn
TROUBLESHOOTING
"
2nd clutch disc worn or seized, seal ring worn
"
1st clutch disc worn or seized, seal ring worn
"
R clutch disc worn or seized, seal ring worn
"
Defective operation of H clutch ECMV
"
Defective operation of L clutch ECMV
"
Defective operation of 4th clutch ECMV
"
Defective operation of 3rd clutch ECMV
"
Defective operation of 2nd clutch ECMV
"
m
Defective operation of 1st clutch ECMV
"
Defective operation of R clutch ECMV
(7)
H-6
20-1109
TROUBLESHOOTING H-7
H-7 Time lag is excessive when starting or shifting gear

• Is there any external oil leakage from the piping or valve joints?
• Is operation of control valve normal?
Checking for abnormalities Clutch combination table

• See the STANDARD VALUE TABLE to check
Clutch
if the time lag is actually excessive. No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
1 Abnormal noise comes from pump
2 There is time lag when transmission is placed in any speed range
3 F1 is normal, but there is time lag when shifting to F2
4 F2 is normal, but there is time lag when shifting to F1
5 F1 and F2 are normal, but there is time lag when shifting to F3
6 F1, F2, and F3 are normal, but there is time lag when shifting to F4
7 F1 - F5 are normal, but there is time lag when shifting to F6
8 F3, F5, and F7 are normal, but there is time lag when in other speed ranges
9 There is time lag in R
10 Transmission modulating pressure is low when placed in any speed range
11 Torque converter oil temperature goes above operating range
20-1110 HD465-7, HD605-7

!
Causes
C
Clogged strainer
b
"
Defective pump
HD465-7, HD605-7
d
Defective oil tightness in rotating clutch
TROUBLESHOOTING
"
Defective shaft seal ring in rotating clutch circuit
"
Drop in set pressure of main relief valve
"
H clutch disc worn or defective seal ring, worn groove
"
L clutch disc worn or defective seal ring, worn groove
"
4th clutch disc worn or defective seal ring, worn groove
"
3rd clutch disc worn or defective seal ring, worn groove
"
2nd clutch disc worn or defective seal ring, worn groove
"
1st clutch disc worn or defective seal ring, worn groove
"
m
R clutch disc worn or defective seal ring, worn groove
"
Defective operation of H clutch ECMV
"
Defective operation of L clutch ECMV
"
Defective operation of 4th clutch ECMV
"
Defective operation of 3rd clutch ECMV
"
Defective operation of 2nd clutch ECMV
"
Defective operation of 1st clutch ECMV
"
Defective operation of R clutch ECMV
(7)
20-1111
H-7
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high

• Does oil temperature go up when torque converter is stalled and go down when torque converter is not
stalled?
Yes = Normal (If torque converter is stalled frequently, however, selection of speed range is
incorrect)

• Is oil level in transmission case correct?

• Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high.
# If oil temperature is normal but oil temperature gauge on machine goes above operating rangey
$ defective oil temperature gauge
Oil leakage inside torque converter (defective seal ring, loose bolt,
Defective operation of torque converter relief valve
Causes
crack in pump, turbine)

Clogged strainer
Defective pump
Clogged filter
Torque
Tank-punp converter
a b c d e f
Remedy
No. C × ×
Problems " " "
1 Pump makes abnormal noise when oil temperature is low
2 High idling and low idling speeds are low
3 Torque converter outlet port oil pressure is low
4 Torque converter inlet port oil pressure is low
5 Transmission modulating pressure is low
6 Excessive leakage inside torque converter
If troubleshooting shows
that all other items are
normal, this is the cause.
20-1112 HD465-7, HD605-7

!
TROUBLESHOOTING H-9
H-9 Torque converter oil pressure is low

• Is there any external oil leakage from the piping or valve joints?

• Pump outlet port oil pressure
Clogged hydraulic pump suction strainer or suction of air into circuit
Drop in set pressure of torque converter relief valve
Excessive leakage inside torque converter

Causes
Defective hydraulic pump
a b c d
Remedy
No. C
✕ ✕ ✕
Problems
1 Abnormal noise comes from pump
2 Oil pressure is low between pump and relief valve
3 Torque converter inlet port pressure is low

Transmission and lock-up pressures are normal, but torque
4
converter inlet pressure is low
When set pressure of torque converter relief valve is adjusted,
5
inlet pressure becomes high
HD465-7, HD605-7 20-1113

➁
TROUBLESHOOTING H-10
H-10 Front brake is ineffective, or effective only on one side

• Is the brake pedal play correct?
• Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in front brake accumulator gas pressure (gas leakage, defective

• Is the tire inflation and tread condition nor-
mal?
• Is any failure code related to the brakes
displayed?
Air sucked in at suction side of brake operating pump

• Is the front brake cut-off switch turned on?
Defective brake operating pump drive system (PTO)
Defective front brake accumulator charge valve
Defective operation of front brake cut valve

Causes
Defective wheel brake piston seal

Defective brake operating pump
Defective brake valve (front)
Air in brake circuit

piston seal
a b c d e f g h i
Remedy
No. ✕ ✕
✕ ✕ ✕ ✕ ✕
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Extremely large operating effort is needed to obtain specified

braking effect
5 Hydraulic and steering do not work
6 Abnormal noise is heard from around PTO
7 Abnormal noise is heard from around transmission oil pan or

PPC pump
8 Accumulator charge pressure is low
9 Brake immediately loses power after engine is stopped
10 There is time lag before brake starts to take effect
11 Brake oil pressure is low
12 When air is bled from brake system, air comes out
13 When front brake cut-off switch is turned ON (When its lower

part is pressed), front brake is not released
20-1114 HD465-7, HD605-7

➁
H-11 Rear brake is ineffective, or effective only on one side

• Is the brake pedal play correct?
• Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in rear brake accumulator gas pressure (gas leakage, defective

• Is the tire inflation and tread condition nor-
Defective retarder solenoid valve (Proportional reducing valve)

mal?
• Is any failure code related to the brakes dis-
played?
Air sucked in at suction side of brake operating pump

Defective brake operating pump drive system (PTO)
Defective rear brake accumulator charge valve
Defective operation of wheel brake piston

Causes
Defective wheel brake piston seal

Defective brake operating pump
Breakage inside wheel brake

Defective brake valve (rear)
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Air in brake circuit
Improper axle oil

piston seal
a b c d e f g h i j k l m n O
Remedy
No. ✕ ✕ ✕
✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
5 Extremely large operating effort is needed to obtain specified

braking effect
6 When brakes are applied, abnormal noise is heard from brake

portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard from around transmission oil pan or

PPC pump
10 When oil is drained from inside axle case, large amounts of

metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
HD465-7, HD605-7 20-1115

➁
H-12 Steering wheel is heavy

• Is the oil level in the hydraulic tank correct?
• Is there any external oil leakage between the pump and steering valve?
• Is the steering wheel play correct?
• Is any failure code related steerings displayed?

• Operating effort of steering wheel
• Time taken to turn the steering wheel from
lock to lock
• Relief pressure of steering circuit
Drop in relief valve set pressure or defective sealing
Defective operation of spool or stuck spool

Causes
Defective opening of check valve

Air sucked in at suction end
Defective steering cylinder

Defective steering pump
Defective steering valve

Crushed suction tube
Defective hoist pump

Clogged strainer
Demand
valve
a b c d e f g h i j
Remedy A
No. C ✕ ✕ ✕
✕ ✕
Problems ✕
1 Circuit pressure is too high at engine low idling or pressure

rises to relief pressure
2 Relief pressure in steering circuit is too low
3 Hoist force is also low
4 Item 3 is abnormal and noise of oil blowing is heard from relief

valve
5 Relief pressure is low at end of cylinder stroke

(Items 1 – 4 normal)
7 When steering wheel is turned to right (left), oil flows out

continuously when hose on opposite side is removed
8 Condition is normal at engine low idling
9 Pump discharge amount is too low
10 Item 3 is normal but speed is slow
11 Excessive play in steering wheel
20-1116 HD465-7, HD605-7

➁
H-13 Steering wheel does not work

• Is there any external oil leakage between the
pump and steering valve?
• Is the steering wheel play correct?
• Is any failure code related steerings dis-
played?


• Relief pressure
Causes

Air sucked in at suction end
Defective steering cylinder

Defective steering valve

Defective hoist pump

Clogged strainer Demand
valve
a b c d e f g h i j k
Remedy A
No. C ✕ ✕ ✕ ✕
Problems ✕
1 Hoist cylinder also does not work
2 When pressure pickup port plug is removed and engine is

cranked, no oil comes out
3 Circuit pressure is too high at engine low idling, or pressure

rises to relief pressure (Item 2 normal)
4 Hoist is normal
5 Relief pressure is low at end of cylinder stroke (Item 4 normal)
6 Item 5 is abnormal and noise of oil blowing is heard from relief

valve
8 Steering wheel works when engine is at low idling
9 When steering wheel is turned to right (left) and hose on oppo-

site side is removed, rod does not move but oil flows out
10 Pump discharge amount is too low
11 Excessive play in steering wheel
H-14 Steering wheel vibrates

• Is any failure code related steerings displayed?
Causes Remedy
Air in hydraulic oil C
Leakage of air inside steering cylinder ✕
HD465-7, HD605-7 20-1117

➁
H-15 Hoist cylinder lacks lifting force (lifting speed)

• Is the actuation of the control levers normal?
• Is the input signal value of the dump lever in the normal range?
• Is any failure code related dump bodys dis-
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
played?
• Is there any external oil leakage from the
pump
and cylinder?
Drop in safety valve set pressure or defective sealing


• Relief pressure
• Body lifting speed

Causes
Drop in performance of hydraulic pump
Drop in performance of steering pump

Defective hoist cylinder

Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C ✕ ✕ C ✕ ✕
✕ ✕ ✕
Problems
1 Steering wheel is also heavy
2 Steering wheel is normal
3 Item i is defective and hoist circuit relief pressure is low

Item 3 is abnormal and noise of oil blowing is heard from relief
4
valve
Hoist circuit pressure is too high at engine high idling
5
(Items 1 – 4 are normal)
6 Only hoist circuit relief pressure is low
7
valve
8 Dump body rises irregularly
9 Pump discharge amount is low
10 Measured dump EPC valve oil pressure is low
11 Excessive hydraulic drift of hoist cylinde
12 Items 1 – 9 are normal but dump body lifting speed is slow
20-1118 HD465-7, HD605-7

➁
H-16 Hoist cylinder does not work

Yes = Seizure, damage to equipment
• Had drop in lifting speed or other symptoms
appeared before?
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
Yes = Worn parts, deteriorated spring, etc.

Drop in safety valve set pressure or defective sealing

• Is the input signal value of the dump lever in

the normal range?
• Is any failure code related dump bodys

displayed?

Causes

• Relief pressure
Crushed pump suction tube
Defective hydraulic pump
Defective hoist cylinder
Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C ✕ ✕ ✕ ✕ ✕
Problems ✕
✕ ✕ ✕
When pressure pickup port plug is removed and engine is
1
cranked, no oil comes out
2 Steering also does not work
3 Steering is normal, only hoist does not work
4 In Item 2, hoist circuit relief pressure is low

5
valve
6 Only hoist circuit relief pressure is low at engine high idling
7
valve
Hoist circuit pressure is too high at engine low idling or
8
pressure rises to relief pressure (Items 1 - 5 normal)
9 Works when engine is at low idling
10 Pump discharge amount is low

When hoist lever is operated to RAISE, and hose on opposite
11
side is removed, cylinder does not move, but oil comes out
12 Measured dump EPC valve oil pressure is low
HD465-7, HD605-7 20-1119

➁
H-17 Excessive hydraulic drift of dump body

• IIs any failure code related dump bodys displayed?

• Hydraulic drift of cylinder
Causes
Defective hoist cylinder piston ring
Defective sealing of valve spool
a b
Remedy
No. ✕ ✕
Problems
1 When engine is stopped with Oil continues to flow out

body fully raised and head pip-
2 ing is removed Oil does not continue to flow out
20-1120 HD465-7, HD605-7

➁
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Points to remember when troubleshooting.................................................................................................20-1152

Method of using troubleshooting charts .....................................................................................................20-1153
S- 1 Starting performance is poor (starting always takes time) .............................................................20-1156
S- 2 Engine does not start ....................................................................................................................20-1159
a) Engine does not turn ................................................................................................................20-1159
b) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............................20-1160
c) Exhaust smoke comes out but engine does not start (fuel is being injected) ..........................20-1162
S- 3 Engine does not pick up smoothly (follow-up is poor) ...................................................................20-1164
S- 4 Engine stops during operations .....................................................................................................20-1166
S- 5 Engine does not rotate smoothly (hunting) ....................................................................................20-1168
S- 6 Engine lacks output (or lacks power).............................................................................................20-1170
S- 7 Exhaust smoke is black (incomplete combustion) ........................................................................20-1172
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................20-1175
S- 9 Oil becomes contaminated quickly ...............................................................................................20-1176
S-10 Fuel consumption is excessive ......................................................................................................20-1177
S-11 Oil is in cooling water, or water spurts back, or water level goes down ........................................20-1178
S-12 Oil pressure caution lamp lights up (drop in oil pressure)..............................................................20-1179
S-13 Oil level rises .................................................................................................................................20-1180
S-14 Water temperature becomes too high (overheating) ....................................................................20-1181
S-15 Abnormal noise is made ................................................................................................................20-1182
S-16 Vibration is excessive ....................................................................................................................20-1183
HD465-7, HD605-7 20-1151

(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior a problem with the method of operation, etc.
investigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the Use the results of the investigation and inspec-
machine before the failure occurred? tion in Items 2 – 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure
this? exactly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
20-1152 HD465-7, HD605-7

(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections + in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information that he has obtained from the
user and the results of that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are
marked with , and of these, causes that have a
high probability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for
items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HD465-7, HD605-7 20-1153

(7)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• Insufficient intake of air
• Defective condition of fuel injection
• Excessive injection of fuel
20-1154 HD465-7, HD605-7

(7)
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
HD465-7, HD605-7 20-1155

(7)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor Causes
• Defective electrical system
Defective preheating circuit (when starting in low temperatures)

• Insufficient supply of fuel
• Improper selection of fuel
• Defective HPI sensor
• Defective HPI actuator
Defective contact of valve, valve seat
Clogged timing rail actuator screen

Loose piping, fuel filter, entry of air
Defective or deteriorated battery

Worn piston ring, cylinder liner
Defective alternator regulator

Clogged air cleaner element
Defective injector check ball

Clogged fuel filter, strainer
Cut, worn injector O-ring

Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period
Starting performance became worse gradually
Engine starts easily when warm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Starting motor cranks engine slowly
When engine is Little fuel comes out even when injection pump sleeve nut is loosened
cranked with
starting motor, Little fuel comes out even when fuel filter air bleed plug is loosened
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly

When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary
When pressure at outlet port of fuel pump is measured, it is found to be low
Inspect fuel pump directly
Troubleshooting
Inspect fuel shut-off valve directly

Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with Yes
engine at low idling? No
Inspect sensor directly (Output voltage and resistance)
Inspect actuator directly (Resistance and filter for clogging)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-1156 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-1
Causes 1.If the following error codes are displayed, carry out
the troubleshooting in "ENG mode". (If any of the fol-
lowing error codes is not displayed, they are not
probably the cause of the trouble. In this case,
inspect the other devices for the cause.)
Defective intake manifold temperature sensor
[C514LK]: Abnormality in fuel rail actuator

Defective atmospheric pressure sensor
[C112LK]: Abnormality in timing rail actuator

Defective fuel pump pressure sensor
Defective timing rail pressure sensor
Defective water temperature sensor
[C318LK]: Abnormality in fuel pump actuator

Defective fuel rail pressure sensor
Defective fuel pump actuator ( 1)

Defective timing rail actuator ( 1)
Defective boost pressure sensor
Defective fuel rail actuator ( 1)

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1157

(7)
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine does not turn
General causes why engine does not turn

• Internal parts of engine seized
a See Troubleshooting S-4. Causes
• Defective electrical system
• Problem in power train (troubleshooting for machine)
a See the manual for the machine.
Defective safety relay or safety switch

Defective battery terminal connection
Defective starting circuit wiring

Broken flywheel ring gear
Defective starting switch
Defective starting motor

Defective battery relay
Questions
Condition of horn when starting Horn does not sound

switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items
Speed of rotation is low

When starting switch is turned Makes grating noise
to START, starting pinion moves
out, but Soon disengages again
Makes rattling noise and does not turn
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
There is no 24V between battery relay terminal B and terminal E
OFF, connect cord,
and carry out When terminal B and terminal C of starting motor are connected, engine starts
troubleshooting at When terminal B and terminal C of safety relay are connected, engine starts
1.
ON
When terminal of safety switch and terminal B of starting motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
Remedy
1. Carry out troubleshooting of machine
HD465-7, HD605-7 20-1159

(7)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
• Defective HPI sensor Causes

Defective fuel shut-off valve wiring

Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
Questions
Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
When fuel filter is drained, fuel does not come out
Check items
There is leakage from fuel piping

Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with Fuel pump outlet port coupler is pushed, almost no fuel comes out
starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting
Inspect fuel pump drive shaft directly

Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
20-1160 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-2
1.If the following error codes are displayed, carry out

Causes probably the cause of the trouble. In this case,
Defective intake manifold temperature sensor
Defective water temperature sensor



Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1161

(7)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start (fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
• Insufficient supply of fuel Causes
Defective dynamic valve system (valve, rocker arm, etc.)

• Improper selection of fuel and oil
Defective preheating heater circuit

Clogged timing actuator screen

Defective fuel pump
Defective injector
Suddenly failed to start
Questions

Starts when engine is warm
When preheating, preheating indicator lamp does not light up
When fuel filter is drained, no fuel comes out
Check items

Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with starting
motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel

Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly

When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
20-1162 HD465-7, HD605-7

(7)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective water temperature sensor Causes
HD465-7, HD605-7
Replace Defective intake manifold temperature sensor
Replace Defective fuel rail actuator ( 1)
TROUBLESHOOTING
Replace Defective timing rail actuator ( 1)

Replace Defective fuel pump actuator ( 1)
Replace Clogged fuel rail actuator

(7)
20-1163
S-2
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly Causes
• Defective condition of fuel spray
• Improper fuel used
• Abnormality in fuel control system
Defective contact of valve and valve seat


• Normal output is not applied
Failure boost pressure sensor

o See Troubleshooting S-6

Improper valve clearance

Seized turbocharger
Defective fuel pump

Defective injector
Engine pick-up suddenly became worse
Questions

Rust and water are found when fuel is drained
When engine is cranked Fuel pump outlet port coupler is pushed, almost no fuel comes out
with starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Blue under light load

Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Noise of interference is heard from around turbocharger
High idling speed under no load is normal, but speed suddenly drops when load is applied

When turbocharger is rotated by hand, it is found to be heavy
Inspect valve clearance directly
Troubleshooting

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
20-1164 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-3
Air leakage from piping between turbocharger and cylinder head

Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1165

(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
• Seized parts inside engine
• There is overheating Causes
a See Troubleshooting S-14.
Broken dynamic valve system (valve, rocker arm, etc.)

• Problem in power train (troubleshooting for machine)
Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)

Failure in power train (troubleshooting for machine)


Broken, seized piston, connecting rod
Broken fuel pump drive shaft

Broken, seized gear train
Defective injector
Abnormal noise was heard and engine stopped suddenly
Engine overheated and stopped
Condition when engine stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel level caution lamp lights up
Metal particles are found when oil is drained
Does not turn at all
When it is attempted
Check items
Turns in opposite direction

to turn by hand using
barring tool Moves amount of gear backlash
Fuel pump shaft does not turn
Engine turns, but stops when load is applied to machine

Carry out troubleshooting of machine
Inspect piston, connecting rod directly

Inspect main bearing, connecting rod directly
Inspect gear train directly
Troubleshooting

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
Add
20-1166 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-4


Defective fuel shut-off valve

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
HD465-7, HD605-7 20-1167

(7)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
Causes
• Air in fuel system
• Defective governor mechanism
High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator

Defective actuation of fuel rail actuator
Defective injector check ball


Defective fuel pump
Defective injector
Questions
Occurs at a certain speed range

Occurs at low idling
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
Engine speed sometimes rises too far
Engine is difficult to stop

Troubleshooting

When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1168 HD465-7, HD605-7

(7)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective fuel pump actuator ( 1)
Causes
HD465-7, HD605-7
— Defective in throttle sensor
Replace Defective in speed sensor
TROUBLESHOOTING
Replace Clogged fuel rail actuator screen

Replace Clogged timing rail actuator screen
this case, inspect the other devices for the cause.)
played, it is not probably the cause of the trouble. In
1.If the following error code is displayed, carry out the
troubleshooting in "ENG mode". (If it is not dis-
(7)
20-1169
S-5
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

a Measure the engine speed and judge if the problem is in the engine or on the machine.
General causes why engine lacks output
• Insufficient intake of air Causes
(if non-specified fuel is used, output drops)
• There is overheating
a See Troubleshooting S-14.

Improper adjustment of valve clearance


Seized turbocharger, interference


Defective fuel pump

Defective injector
Suddenly
Power was lost
Questions
Gradually
Dust indicator lamp is red
Black
Check items

Engine pickup is poor and combustion is irregular
High idling speed of engine is low

Troubleshooting

Check part No. of controller calibration data
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
20-1170 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-6
High resistance or clogged fuel circuit

Defective controller calibration data

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
—
—
HD465-7, HD605-7 20-1171

(7)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• Defective condition of fuel injection Causes
Leakage of air between turbocharger and cylinder head


Improper adjustment of valve clearance
Failure timing rail pressure sensor

Seized turbocharger, interference

Crushed, clogged muffler

Defective fuel pump
Defective injector
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly

Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated ( 2)
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-1172 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-7

2.If an error code of the timing rail pressure sensor
system is displayed, carry out the troubleshooting in
"EA mode".
HD465-7, HD605-7 20-1173

(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

a To prevent the oil from leaking up or down in the turbocharger, do not run the engine at idling for more than
20 minutes continuously (both low and high idling).
General causes why oil consumption is excessive
Causes
• Abnormal combustion of oil
• External leakage of oil
• Wear of parts in lubrication system
Worn seal at turbine end

Worn seal at blower end
Worn, damaged valve (stem, guide, seal)
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system
Leakage from oil filter or oil cooler

Leakage from oil drain plug

Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping

Broken piston ring
Broken oil cooler

Turbocharger
Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake pipe is dirty with oil
Check items
Inside of exhaust pipe is dirty with oil

There is oil in engine cooling water
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
Troubleshooting
When intake manifold is removed, inside is found to be dirty with oil

Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
HD465-7, HD605-7 20-1175

(7)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Defective combustion
Causes
• Operation under excessive load
• Oil change interval is too long
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
Clogged breather, breather tube

Worn valve (stem, guide, seal)
Defective oil filter safety valve

Too much engine oil added
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)
Check items
Engine oil temperature rises quickly

Black
Excessive
Amount of blow-by gas
None
Inspect turbocharger lubrication drain tube directly
Troubleshooting S-7
Troubleshooting
Excessive play of turbocharger shaft

Inspect breather element directly
Carry out
Inspect oil cooler directly

Inspect oil filter directly
Inspect safety valve directly
Replace
Replace
Replace
Replace
Correct
eplace
Clean
Clean
Clean
Remedy
20-1176 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel
• Defective condition of fuel injection
• Defective HPI sensor Causes
High resistance, clogged fuel return circuit

Failure timing rail pressure sensor
Leakage of fuel inside head cover

Failure fuel rail pressure sensor

Defective fuel pump
Defective injector
Questions
More than for other machines of same model

Condition of fuel consumption Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Check items
Black
Exhaust smoke color
White
Inspect inside of head cover directly

Troubleshooting

Abnormality in fuel rail pressure sensor system is indicated ( 1)
Abnormality in timing rail pressure sensor system is indicated ( 1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1. If an error code of the fuel rail pressure sensor system or timing rail pressure sensor
Correct
Clean
Clean
system is displayed, carry out the troubleshooting in "EA mode". Remedy
HD465-7, HD605-7 20-1177

(7)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
Broken power train oil cooler (troubleshooting for machine)

Damaged cylinder liner O-ring, holes caused by pitting
Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Broken water pump seal
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Check items
Engine oil level has risen, oil is cloudy white

Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Troubleshooting
Carry out pressure-tightness test of cylinder head

Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Replace
Replace
Replace
Replace
Replace
Replace
Remedy Replace
20-1178 HD465-7, HD605-7

(7)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure caution lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper selection of fuel (insufficient viscosity) Causes
• Deterioration of oil due to overheating
Clogged, broken oil pump suction pipe

Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping

Clogged oil pan suction strainer
Defective oil pump relief valve
Defective oil pressure sensor

Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler

Clogged oil filter
Water, fuel in oil

Questions
Non-specified oil is being used

Engine oil pressure caution lamp lights up
Lights up at low idling
Lights up at low, high idling
Condition when oil pressure lamp lights up
Lights up on slopes
Sometimes lights up
Oil level caution lamp lights up (machines equipped with caution lamp)
Check items
There is crushing, external leakage from hydraulic piping

Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found

Carry out Troubleshooting
Inspect suction strainer, pipe directly

Troubleshooting
Oil pump rotation is heavy, there is play

Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure lamp goes out
(machines equipped with oil level sensor)
S-13
When oil pressure is measured, it is found to be normal

Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
HD465-7, HD605-7 20-1179

(7)
S-13 Oil level rises

a If there is oil in the cooling water, carry out Troubleshooting S-11.
General causes why oil level rises
• Cooling water in oil (milky white)
• Fuel in oil (diluted, and smells of diesel fuel) Causes
• Entry of water or oil from other component
Clogged water pump drain hole (breather hole), defective seal
Defective auxiliary equipment (pump, compressor) seal

Defective cylinder head injector sleeve
Broken, broken rear oil seal face

Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal

Broken aftercooler core
Worn fuel pump seal

Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in cooling water
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles
appear, or water spurts back
Check items
Exhaust smoke is white

Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank

Troubleshooting
Inspect rear oil seal directly

Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1180 HD465-7, HD605-7

(7)
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Rise in oil temperature in power train Causes
(troubleshooting for machine)
Rise in power train oil temperature (troubleshooting for

Defective radiator cap (pressure valve)
Defective water temperature gauge

Defective operation of thermostat

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core

Lack of cooling water
Broken water pump
machine)
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level caution lamp lights up (machines equipped with caution lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on cooling water
Excessive air bubbles inside radiator, water spurts back
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Check items
Water is leaking because of cracks in hose or loose clamps

When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Cooling water flows out from overflow hose
Power train oil temperature enters red range faster than engine water temperature
When compression pressure is measured, it is found to be low Carry out troubleshooting of machine
Inspect oil cooler directly
Troubleshooting
Inspect radiator core directly

When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
Carry out function test on thermostat (cracking temperature)
When water temperature is measured, it is found to be normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
HD465-7, HD605-7 20-1181

(7)
S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external noise.
General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion noise Causes
• Air sucked in from intake system
Air leakage from auxiliary equipment (pump, compressor)

Broken dynamic valve system (valve, rocker arm, etc.)
Defect inside muffler (dividing board out of position)

Leakage of air between turbocharger and head
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference

Seized turbocharger, internal interference
Defective adjustment of valve clearance
Missing, seized gear bushing

Improper gear train backlash
Seized crankshaft bearing
Defective injector
Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
Check items
Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine

Troubleshooting
When muffler is removed, abnormal noise disappears

Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
20-1182 HD465-7, HD605-7

(7)
S-16 Vibration is excessive

a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment between engine and chassis
• Abnormal combustion Causes
Defective dynamic valve system (valve, rocker arm, etc. stuck)
Internal damage in clutch chamber or damper chamber

Loose engine mounting bolts, broken cushion
Worn front support spigot joint portion
Worn main bearing, connecting rod
(troubleshooting for machine)

Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
Questions
Suddenly increased
Condition of vibration
Gradually increased
Seal on injection pump has come off
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black

Inspect main bearing, connecting rod directly
Troubleshooting
Inspect cam bushing directly

Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
HD465-7, HD605-7 20-1183

(7)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................30- 3 FRONT WHEEL

PRECAUTIONS WHEN CARRYING Removal and Installation.......................... 30-81
OUT OPERATION .......................................30- 4 REAR WHEEL
SPECIAL TOOL LIST................................. 30-5-1 Removal ................................................... 30-82
FUEL INJECTION PUMP Installation ................................................ 30-83
Removal and Installation ..........................30- 6 FRONT BRAKE CALIPER PADS
RADIATOR Removal and Installation.......................... 30-84
Removal....................................................30- 7 FRONT BRAKE CALIPERS
Installation.................................................30- 8 Removal and installation .......................... 30-85
ENGINE AND TORQUE CONVERTER AND Disassembly and Assembly ..................... 30-86
TRANSMISSION OIL COOLER FRONT WHEEL HUB
Removal and Installation ..........................30- 9 Disassembly............................................. 30-88
ENGINE FRONT SEAL Assembly.................................................. 30-89
Removal and Installation ..........................30-10 FINAL DRIVE CARRIER
OUTPUT SHAFT Removal and installation .......................... 30-91
Removal and Installation ..........................30-11 Disassembly and Assembly ..................... 30-92
Disassembly .............................................30-12 FINAL DRIVE AND REAR BRAKE
Assembly ..................................................30-13 Removal ................................................... 30-93
ENGINE REAR SEAL Installation ................................................ 30-95
Removal and Installation ..........................30-15 SKETCH OF SPECIAL TOOL ..................... 30-96
CYLINDER HEAD FINAL DRIVE, REAR BRAKE AND
Removal....................................................30-17 PARKING BRAKE
Installation.................................................30-19 Removal and Installation ......................... 30-97
ENGINE Disassembly............................................. 30-98
Removal....................................................30-22 Assembly................................................ 30-103
Installation.................................................30-23 FRONT SUSPENSION CYLINDER
TORQUE CONVERTER AND TRANSMISSION Removal ................................................. 30-109
Removal....................................................30-25 Installation .............................................. 30-110
Installation.................................................30-26 Disassembly............................................30-111
TRANSMISSION AND TORQUE CONVERTER Assembly................................................ 30-112
Separation and Coupling ..........................30-28 REAR SUSPENSION CYLINDER
TORQUE CONVERTER Removal and Installation........................ 30-114
Disassembly .............................................30-29 Disassembly........................................... 30-115
Assembly ..................................................30-33 Assembly................................................ 30-116
TRANSMISSION RETARDER COOLING PUMP
Disassembly .............................................30-39 Removal and Installation........................ 30-118
Assembly ..................................................30-52 STEERING, HOIST, AND HOIST CONTROL
DIFFERENTIAL PUMP
Removal....................................................30-67 Removal and Installation........................ 30-119
Installation.................................................30-68
Disassembly .............................................30-69
Assembly ..................................................30-73
HD465-7, HD605-7 30-1

➃
TORQUE CONVERTER, TRANSMISSION
AND RETARDER COOLING, AND BRAKE
PUMP
Removal and Installation ........................30-120
STEERING VALVE
Disassembly ...........................................30-122
Assembly ................................................30-125
DEMAND VALVE
HOIST VALVE
STEERING CYLINDER
Disassembly ...........................................30-134
Assembly ................................................30-135
HOIST CYLINDER
Disassembly ...........................................30-137
Assembly ................................................30-138
DUMP BODY
Removal..................................................30-141
Installation...............................................30-142
OPERATOR'S SEAT
Disassembly ...........................................30-144
Assembly ................................................30-149
30-2 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY .....Title of operation
..............................................................Precautions related to safety when carrying out the opera-
tion
1. X X X X (1) ...........................................Step in operation
★...........................................................Technique or important point to remember when removing
XXXX (1).
2. (2): .................................... Indicates that a technique is listed for use during
installation
3. assembly (3)
..................................................Quantity of oil or water drained
INSTALLATION OF cccc ASSEMBLY ....Title of operation

• Carry out installation in the reverse order to removal.
....................................................Technique used during installation
★...........................................................Technique or important point to remember when installing
(2).
• Adding water, oil ...............................Step in operation
★...........................................................Point to remember when adding water or oil
...................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
HD465-7, HD605-7 30-3

➂
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATIONL
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
1. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
2. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HD465-7, HD605-7 30-5

➂
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79 T- - can not be supplied (they are items to be locally manufactured).
★ Necessity: ■ : .......Cannot be substituted, should always be installed (used)
● : .......Extremely useful if available, can be substituted with commercially available part.
New/remodel:N : .......Tools with new part numbers, newly developed for this model.
R : .......Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank....Tools already available for other models, used without any modification
★ Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Nece N ew / Ske-
Component Symbol Part No. Part Name -ssity Q ’ty del tch
rem o Nature of work, remarks
795-799-5410 Adapter ■ 1
A Removal, installation of injec-
tor assembly
795-799-5420 Remover ■ 1
795-621-1140 Push tool ■ 1
A2 795-902-1460 Bolt ■ 3 Installation of engine front

seal
01582-02218 Nut ■ 3
Disassembly, assembly of
engine assembly 795-621-1130 Push tool ■ 1
A3 Installation of engine rear seal
01050-32280 Bolt ■ 5
792-420-1110 Centering tool ■ 1
• 792-420-1120 • Flange 2 Centring engine assembly and

C4 torque converter, transmission
• 790-413-1120 • Color 1 assembly
• 01010-51230 • Bolt 8
790-501-5000 Unit repair stand ■ 1

1 790-901-2110 Bracket ■ 1 trque converter assembly
Disassembly, assembly of C 790-901-3011 Plate ■ 1
torque convertor assembly
2 790-101-1871 Nut wrench ■ 1 Removal, installation of PTO
nut
3 792-103-5110 Wrench ■ 1 Removal, installation of pump
nut
Disassembly, assembly of • 792-420-1120 • Flange 2 Centring engine assembly and

torque convertor C4 torque converter, transmission
transmission assembly • 790-413-1120 • Color 1 assembly
• 01010-51230 • Bolt 8
Disassembly, assembly of D1 799-301-1600 Oil leak tester ■ 1 Checking actuation of piston
transmission assembly
Disassembly, assembly of dif-
1 790-901-5110 Bracket ■ 1 ferential assembly
Disassembly, assembly of H
diffelential assembly
790-901-3420 Plate ■ 1
2 790-425-1660 Wrench ■ 1 Adjust side bearing preload
30-5-1 HD465-7, HD605-7

➃
Nece New/ Ske-

Component Symbol Part No. Part Name -ssity Q’ty del tch
remo Nature of work, remarks
3 790-102-1130 Power wrench t 1 Removal, installation of bear-
ing cap bolt
diffelential assembly H
4 797-101-1171 Power wrench t 1 Removal, installation of pin-
ion bearing lock nut
792T-422-1610 Spacer t 4 N Q
1 01010-61620 Bolt t 4
01643-31645 Washer t 4
Disassembly, assembly of 2 795-102-2102 Spring washer t 1 Removal, installation of spring

final drive and rear brake, J
parking brake assembly 792-520-2110 Installer t 1 Removal, installation of floa-
3 tin seal
792-520-1600 Push tool t 1 (for small diameter)
791-585-1510 Installer t 1 Removal, installation of floa-

4 tin seal
792-530-1700 Push tool t 1 (for large diameter)
792-103-4102 Push tool t 1
792-625-1300 Push tool t 1 Press fitting of bushing

1 (for front)
790-101-5421 Grip t 1 (for rear)
suspension cylinder Q 01010-81240 Bolt t 1
assembly
792-610-1000 Suspension tool t 1
Adjusting of suspension cylin-
2 • 792-610-1100 • Pump assembly 1 der
• 792-610-1200 • Charging tool 1
1 790-452-1200 Pilot ring tool t 1 Centering valve body and
upper case
steerin valve assembly T
2 790-452-1100 Tool installer set t 1 Installation of spacer
790-502-1003 Repair stand t 1

Disassembly and assembly
1
steering cylinder
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench t 1 Removal of cylinder head
3 790-302-1270 Socket t 1 Removal of piston nut
790-201-1702 Push tool KIT t 1
Disassembly, assembly of U 4
• 790-101-1771 • Push tool KIT t 1
Press fitting of bushing
steering cylinder assembly
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
790-201-1500 Push tool KIT t 1
• 790-101-1580 • Push tool KIT t 1

5 Press fitting of dust seal
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
HD465-7, HD605-7 30-5-2

(8)
Nece N ew / Ske-
Component Symbol Part No. Part Name -ssity Q ’ty del tch
rem o Nature of work, remarks
6 790-720-1000 Expander ■ 1
steering cylinder assembly U 7 796-720-1650 Ring ■ 1 Removal of steerig cylinder
8 07281-01029 Clamp ■ 1
790-502-1003 Repair stand ■ 1

1 hoist cylinder
790-101-1102 Hydraulic pump ■ 1
2 790-102-3802 Wrench ■ 1 Removal, installation of cylin-

der dead
3 790-720-1000 Expander ■ 1
4 796-720-1680 Ring ■ 1 Removal of piston ring
5 07281-01580 Clamp ■ 1
792-201-7310 Push tool ■ 1

790-101-5421 Grip ■ 1
(for cylinder )
01010-81240 Bolt ■ 1
6 790-201-1702 Push tool KIT ■ 1

Disassembly, assembly of H
hoist cylinder assembly
• 790-201-1851 • Push tool ■ 1
(for cylinder )
• 790-101-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
792-201-7410 Plate ■ 1
Press fitting of dust seal
790-101-5021 Grip ■ 1
(for cylinder )
01010-80816 Bolt ■ 1
7 790-201-1500 Push tool KIT ■ 1
• 790-201-1660 • Push tool ■ 1

Press fitting of dust seal
(for cylinder )
• 790-201-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
Removal of dump body V1 790-441-1320 Hook ■ 1 Lifting of dump body
assembly
799-703-1200 Service KIT tool ■ 1
799-703-1100 Vacuum pump ■ 1

Collection re-use of new X 799-703-1110 Vacuum pump ■ 1
freon gas (220V) Collection charging with freon
Vacuum pump gas
799-703-1120 ■ 1
(240V)
799-703-1400 Gas leak tester ■ 1
30-5-3 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND INSTALLA-

TION OF FUEL INJECTION
PUMP ASSEMBLY
REMOVAL
Stop the truck on level ground and set the park-

ing brake switch to the PARK position, then lock
the wheels with blocks.
Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Close the fuel supply valve.
2. Remove the clamp and move hose (1).
3. Disconnect wiring connector (2).
4. Disconnect fuel hose (3) and fuel tubes (4) and

(5).
5. Remove mounting bolts (6) and fuel pump

assembly (7).
INSTALLATION
• Carry out installation in the reverse order to
removal.
★ Bleed air from the fuel circuit. For details, see

TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
30-6 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLA- 6. Disconnect wiring connector (5) and hose (6)
from the left side of the radiator and move hose
TION OF RADIATOR ASSEM- (7).
BLY
REMOVAL

1. Remove the engine underguard.
2. Drain the cooling water.

7. Disconnect hose (8) from the left bottom of the
Radiator: 69
radiator.
3. Bleed air conditioner refrigerant gas.
4. Remove radiator mask (1) and guard (2).

Mask : 30 kg
Guard : 100 kg
8. Remove tube (9).
9. Disconnect hose (10).
10. Remove hose (11) form the clamp and move it.
5. Disconnect hoses (3) and (4).
HD465-7, HD605-7 30-7

➂
DISASSEMBLY AND ASSEMBLY RADIATOR
11. Disconnect wiring connector (12) of the coolant 15. Remove air conditioner condenser (18), fuel
level sensor above the radiator. cooler (19), steering oil cooler (20), and air after-
cooler (21) from the radiator assembly.
12. Disconnect hoses (13) and (14) above the radia-

tor and remove pipe (15).
INSTALLATION
13. Remove guard (16).
removal.
• Charge the air conditioner circuit with refrig-

erant gas (R134a).
,
Hose clamp:
13.7 ± 0.5 Nm {140 ± 5 kgcm}
★ When using 2 hose clamps continuously, set

their bolts at an angle of 180° to each other.
14. Lift off radiator assembly (17).
• Refilling with water
Radiator assembly: 310 kg Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
Radiator: 69
30-8 HD465-7, HD605-7

➂
ENGINE AND TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY AND TRANSMISSION OIL COOLER

TION OF ENGINE AND
TRANSMISSION OIL COOLER
ASSEMBLY
REMOVAL

1. Remove the engine underguard.
2. Drain the engine oil and hydraulic oil.
Engine oil pan: 57
Hydraulic tank: 122
3. Disconnect hose (1) from the underside of the

cooling fan.
INSTALLATION
removal.
Mounting bolt: Adhesive (LT-2)

Mounting bolt:
4. Disconnect hoses (2) and (3). 245 – 309 Nm {25 – 31.5 kgm}
[Target: 279 Nm {28.5 kgm}]
5. Remove tubes (4) and (5).
• Refilling with oil
6. Supporting the engine and torque converter and Add oil through the oil filler to the specified level.
transmission oil cooler assembly (6) with jacks, Run the engine to circulate the oil through the
system. Then, check the oil level again.
etc., remove them.
Engine oil pan: 57 (EO30-CD)
Engine and torque converter and trans-
mission oil cooler assembly: 140 kg
Hydraulic tank: 122 (EO10-CD)
HD465-7, HD605-7 30-9

➂
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLA- INSTALLATION

TION OF ENGINE FRONT 1. Using tool A2, press fit engine front seal (3) and
SEAL dust seal (2) together to the front cover.
★ Press fitting dimension a of dust seal: 4 mm
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-621-1140 Push tool ■ 1
A2 795-902-1460 Bolt ■ 3
01582-02218 Nut ■ 3
REMOVAL
1. Remove the radiator assembly. For details, see
REMOVAL, INSTALLATION OF RADIATOR 2. Install crank pulley (1).
ASSEMBLY. Mounting bolt:
1st time : 73.5 – 19.6 Nm {7.5 ± 2 kgm}
2. Remove the fan belt. 2nd time : 245.0 – 19.6 Nm {25 ± 2 kgm}
3rd time : 637.0 – 19.6 Nm {65 ± 2 kgm}
3. Remove crank pulley (1).
Crank pulley: 55 kg 3. Carry out the rest of installation work in the
reverse order to removal.
4. Remove dust seal (2) and engine front seal (3).
30-10 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT

INSTALLATION
TION OF OUTPUT SHAFT
ASSEMBLY • Carry out installation in the reverse order to
removal.
★ For application of ENS grease to each part, see
REMOVAL
DISASSEMBLY AND ASSEMBLY.
the wheels with blocks. Mounting bolt: Adhesive (LT-2)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
pin.
1. Remove drive shaft assembly (1).

Mounting bolt:
Drive shaft assembly: 30 kg 98 – 123 Nm {10 – 12.5 kgm}
2. Remove coupling (2).
Mounting bolt:
3. Remove cover (3).
98 – 123 Nm {10 – 12.5 kgm}

Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4. Remove snap ring (4).
5. Remove the bearing and cover (5) together.
★ Use the guide bolt and forcing screws to

remove the bearing and cover.
Cover assembly: 35 kg
6. Lift off output shaft assembly (6).

Output shaft assembly: 90 kg
HD465-7, HD605-7 30-11

➂
DISASSEMBLY AND ASSEMBLY

OF OUTPUT SHAFT ASSEMBLY
DISASSEMBLY
1. Oil cage assembly
Remove oil seal (1) from cover (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Disassembly of damper assembly (5)

1) Before disassembling, make marks of flange
(6), body assembly (7), and body outer (9)
for balancing them after reassembly.
2) Remove body assembly (7) and rubber
pieces (8) from body outer (9).
★ There are 2 rubber pieces (8), large one
and small one. Check their locations.
3) Remove bearing (10) from the flywheel.
30-12 HD465-7, HD605-7

➂
ASSEMBLY 3. Install damper assembly (5) to the flywheel.

Spline of body assembly shaft:
ENS grease
4. Press fit bearing (3) to cover (4).

Bearing: ENS grease
5. Install cover assembly to the flywheel.

Cover assembly: 55 kg
Mating faces of cover assembly and fly-
wheel: Gasket sealant (LG-6)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6. Fit oil seal (1) to cover (2).

Insertion part of cover and outside of oil
seal: LOCTITE 648 (287-01-12830)
★ Degrease and dry the above parts before
applying gasket sealant.
Mating faces of covers (2) and (4):
Gasket sealant (LG-6)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Using the push tool, press fit bearing (10) to the

flywheel.
Inside of bearing: ENS grease
2. Assembly of damper assembly

1) Apply gasket sealant to body outer (9) and
the mating face of flange (6), then install
them.
Mating face of flange:
2) Install body assembly (7).
3) Install body outer (9), body assembly (7),
and rubber pieces (8).
★ When installing large and small rubber
pieces (8), check their locations.
★ Before installing these parts, apply grease to
them.
Body outer, body assembly, and rub-
ber pieces: Grease (G2-LI)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4) Install flange (6).
Mating face of flange:
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
★ When installing the body outer, body inner,
and flange, match them marks to each other.
HD465-7, HD605-7 30-13

➂
7. Install the cage assembly to the cover assembly.
• Procedure for filling ENS grease

1) Part No. of ENS grease: 427-12-11871
2) Parts to be filled with ENS grease, quantity of
ENS grease to be supplied (Total: Approx.
500 g), and parts to be coated with ENS
grease are shown below.
30-14 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

TION OF ENGINE REAR SEAL 1. Using tool A3, press fit engine rear seal (2) until
it comes to the end of the housing.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-621-1130 Push tool ■ 1
A3
01050-32280 Bolt ■ 5
REMOVAL
1. Remove the output shaft assembly. For details,
see REMOVAL, INSTALLATION OF OUTPUT
SHAFT. 2. Install flywheel (1).
★ Secure the flywheel and housing with a stop-
2. Install guide bolt [1] and lift off flywheel (1). per, etc.
Since the faucet joint part of the flywheel is
shallow, the flywheel may fall suddenly. ★ Check each mounting bolt head for punch
Take care. marks. If there are 5 punch marks, replace
Flywheel: 45 kg the bolt.
★ Tighten the mounting bolts to the specified
torque in the following order.
Mounting bolt: Engine oil (EO30-CD)
Mounting bolt:
1st time : 198 ± 19.6 Nm {20 ± 2 kgm}
2nd time : 460.6 ± 19.6 Nm {47 ± 2 kgm}
3rd time : 90° +30°
0
★ When reusing a bolt, make a punch mark on

its head after tightening it.
3. Remove engine rear seal (2).
HD465-7, HD605-7 30-15

➂
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
★ Using dial gauge [2], check the flywheel for

radial runout and facial runout.
• Radial runout: Max. 0.15 mm
• Facial runout: Max. 0.20 mm
3. Carry out the rest of installation work in the

reverse order to removal.
30-16 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLA- 9. Loosen the hose clamp and remove air intake
connector (9).
TION OF CYLINDER HEAD
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-799-5410 Adapter ■ 1
A
795-799-5420 Remover ■ 1
REMOVAL
Stop the truck on level ground and set the park- 10. Remove air intake tube (10).
the wheels with blocks. 11. Remove covers (11) and (12).
12. Disconnect lubrication tubes (13) and (14).
pin.
Disconnect the cable from the negative (–) ter- 13. Disconnect exhaust tube (15).
1. Drain the cooling water.
Radiator: 69
2. Open the engine top cover and remove the bat-

tery case in the rear and engine cover.
3. Remove fuel filter bracket assembly (1).
4. Disconnect fuel tubes (2) and (3).
5. Remove corrosion resistor and bracket assembly

(4).
6. Disconnect each wiring connector and ground 14. Remove turbocharger and exhaust manifold
wire and move wiring harness (4). assembly (16).
7. Remove air intake connectors (6) and (7). Turbocharger and exhaust manifold
assembly: 60 kg
8. Remove air intake manifold (8).
Reference: The same parts are used in the
front and rear sections.
HD465-7, HD605-7 30-17

➂
15. Remove spill tube (30). 20. Remove the mounting bolts and rocker arm
housing (37).
16. Remove cylinder head cover (32).
21. Remove cylinder head mounting bolts (38).

17. Remove rocker arm assembly (33). Using the sling bolts, remove cylinder head
★ Loosen the locknut, then loosen adjustment assembly (39).
screw 2 – 3 turns. Cylinder head assembly: 60 kg
18. Remove cross heads (34) and push rods (35).
19. Using tool A, remove injector assembly (36).
30-18 HD465-7, HD605-7

➂
INSTALLATION
• Carry out installation in the reverse order to Mounting bolt of cylinder head cover:
removal. 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
Fuel tube sleeve nut (2): ★ Clean the mounting bolt holes before install-
ing the bolts.
43 – 47 Nm {4.4 – 4.8 kgm}
★ Check that the ball of the adjustment screw
Fuel tube sleeve nut (3): is fitted to the socket of the push rod.
24 – 27 Nm {2.4 – 2.8 kgm}
Rocker arm mounting bolt:
Engine oil (EO30-CD)
★ Tighten the mounting bolts of the air intake Rocker arm mounting bolt:
manifold in the following order. 235.2 – 254.8 Nm {24 – 26 kgm}
Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
★ Adjust each cross head according to the fol-

lowing procedure.
1) Loosen the locknut and return the adjust-
ment screw until it does not touch the
valve stem.
2) Hold the contact face of the cross head
against the rocker arm and keep the
cross head in contact with the valve stem
on the push rod side.
3) Tighten the adjustment screw gradually.
After it touches the valve stem, tighten it
20° – 30° further.
★ Tighten the mounting bolts of the turbo- 4) Tighten the locknut.
charger and exhaust manifold in the follow-
ing order. Locknut:
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
Mounting bolt of turbocharger and
exhaust manifold assembly:
1st time : 39.2 – 58.8 Nm {4 – 6 kgm}
2nd time :
112.8 – 122.5 Nm {11.5 – 12.5 kgm}
HD465-7, HD605-7 30-19

➂
1) Using tool A, insert injector (60) in the cylin-

der head.
O-ring: Engine oil (EO30-CD)
★ When inserting the injector, check that the
gasket at its end will not fall.
★ Direct the draft hole of the injector toward the
diagonal point of the holder and set the
holder to the installation position, too.
★ Insert the injector straight in the cylinder
head hole. Using the cylinder side of tool A,
press the injector top and set the seal of its
end to the cylinder head.
Rocker arm housing:

★ Apply the gasket sealant in a line 2 – 3 mm in
diameter along the housing groove as shown
below.
Mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
2) Tighten the holder mounting bolts.

★ Measure stem length a of each mounting
bolt. If it is 80 mm or longer, do not use
the bolt but use new one.
Threads and seat of mounting
bolt: Engine oil (EO30-CD)
Mounting bolt:
1st time:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2nd time:
Retighten 90° +30°0
30-20 HD465-7, HD605-7

➂
★ After tightening the bolts, make punch mark

★ Check that there is not foreign matter on the a on the main bolt (Do not make the punch
fitting face of the cylinder head and in the cyl- mark if the bolts are new).
inder.
★ When fitting the gasket, check that the grom-
met is not removed.
★ Check each mounting bolt head for punch
marks. If there are 3 punch marks, replace
the bolt.
★ Tighten the cylinder head mounting bolts in
the following order.
Mounting bolt:
Molybdenum disulfide grease (LM-P)
Cylinder head mounting bolts
( – ):
1st time : 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time : 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time : Make marks on bolts, and • Refilling with water
cylinder head with paint, Add water through the water filler to the specified
then retighten the bolts 90° level. Run the engine to circulate the water
– 120°. through the system. Then, check the water level
Mounting bolts (( – )) again.
93.2 – 103 Nm {9.5 – 10.5 kgm}
Radiator: 69
HD465-7, HD605-7 30-21

➂
DISASSEMBLY AND ASSEMBLY ENGINE

5. Disconnect exhaust tube (5).
TION OF ENGINE ASSEMBLY 6. Disconnect wiring connector E13A (6) and E13B
(7).
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-420-1120 • Flange 2
C4
790-413-1120 • Collar 1
01010-51230 • Bolt 8
REMOVAL
ing brake switch to the PARK position, then lock 7. Remove engine oil cooler tubes (8) and (9).
pin.
1. Remove battery box (1), engine top cover (2)
(2A), air cleaner (3), and air intake tube.
8. Disconnect wiring connectors SIG (10), POW

(11), and ENG (12) from the left rear part of the
engine and remove bracket (13).
2. Remove the radiator assembly. For details, see

REMOVAL, INSTALLATION OF RADIATOR
ASSEMBLY.
3. Remove the radiator cross bar.
4. Remove washer tank (4).
30-22 HD465-7, HD605-7

➂
10. Remove oil filter bracket assembly (17).
12. Disconnect air conditioner pipe (20).
13. Remove plate (21) and drive shaft (22).

Drive shaft: 30 kg
INSTALLATION
removal.
14. Sling the engine assembly temporarily. ★ When tightening the bolts, check that the key
way of the spider cap is fitted to the key way
15. Remove engine mounting bolts (23) and (24) of the mating yoke.
and pull out engine assembly (25) forward to Mounting bolt: Adhesive (LT-2)
remove it. Mounting bolt:
★ When removing the engine assembly, check 98 – 123 Nm {10 – 12.5 kgm}
that the all wires and pipes are disconnected
and take care that the engine assembly will
not interfere with the chassis. ★ Center the engine assembly and torque con-
Engine assembly: 2,750 kg verter and transmission assembly according
HD465-7, HD605-7 30-23

➂
1. Install flange (C4-1) and collar (C4-2) of tool

C4 between coupling (20) on the engine side
and coupling (21) on the torque converter
side.
2. Center the engine assembly and torque con-
verter and transmission assembly by moving
the engine assembly so that collar (C4-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
Reference: The allowable vertical and lateral
deviation between both flanges
is 3 mm maximum.
Engine mount mounting bolt (Both front

and rear):
343 – 426.3 Nm {35.0 – 43.5 kgm}
★ If the engine mount bracket was removed
from the chassis, tighten its mounting bolts to
the following torque.
Mounting bolt of front engine mount
bracket:
343 – 426.3 Nm {35.0 – 43.5 kgm}
Mounting bolt of rear engine mount
bracket:
450 – 608 Nm {50 – 62 kgm}
• Refilling with water

Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
Radiator: 69
30-24 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION
REMOVAL AND INSTALLA- 6. Disconnect hose (4) and tube (5).
TION OF TORQUE CON-

VERTER AND TRANSMISSION
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-420-1120 • Flange 2
C4
790-413-1120 • Collar 1 7. Remove drive shaft (6).
01010-51230 • Bolt 8
Drive shaft: 30 kg
REMOVAl 8. Disconnect hoses (7), (8), (9), (10), and (11).

pin.
1. Remove the transmission underguard.
2. Drain the transmission oil and hydraulic oil.
Transmission case: 190
Hydraulic tank: 122
3. Disconnect wiring connectors (1) (TM2 and TM3).
4. Remove drive shaft (2).

Drive shaft: 65 kg
HD465-7, HD605-7 30-25

➂
9. Disconnect hoses (12), (13), and (14) and tubes Torque converter and transmission
(15) and (16) from the left underside of the trans-
assembly: 1,600 kg
mission.
10. Sling the torque converter and transmission

assembly temporarily.
INSTALLATION
11. Remove mounting bolts (17) and (18) of the front removal.
and rear mounts, then remove torque converter
and transmission assembly (19). ,
★ When removing the torque converter and ★ When tightening the bolts, check that the key
transmission assembly, check that the all way of the spider cap is fitted to the key way
wires and pipes are disconnected and take of the mating yoke.
care that the assembly will not interfere with
the chassis.
★ Check the thickness and quantity of the
shims set in the rear mount.
• Standard thickness of shims: 2 mm Mounting bolt:
• Thickness of each shim: 0.5 mm (1 type) 157 – 198 Nm {16.0 – 20.1 kgm}

Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-26 HD465-7, HD605-7

➂
★ Center the engine assembly and torque con-

verter and transmission assembly according
1. Install flange (C4-1) and collar (C4-2) of tool

C4 between coupling (20) on the engine side
and coupling (21) on the torque converter
side.
2. Center the engine assembly and torque con-
verter and transmission assembly by moving
the engine assembly so that collar (C4-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
Reference: The allowable vertical and lateral
deviation between both flanges
is 3 mm maximum.
★ If the transmission mount bracket was

removed from the chassis, tighten its mount-
ing bolts to the following torque.
Mounting bolt:
450 – 608 Nm {50 – 62 kgm}

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
Transmission case: 190 (EO30-CD)
HD465-7, HD605-7 30-27

➂
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND TORQUE CONVERTER
SEPARATION AND COUPLING 5. Lift off torque converter assembly (9).

OF TRANSMISSION ASSEM- Torque converter assembly: 410 kg
BLY AND TORQUE CON-
6. Remove seal rings (10) and (11).
VERTER ASSEMBLY
SEPARATION
1. Remove pump assemblies (1), (2), and (3) and
their pipes.
Retarder cooling pump assembly (1):
30 kg
Steering hoist and hoist control pump
assembly (2): 35 kg
Torque converter, transmission, retarder
cooling, and brake pump assembly (3):
25 kg
2. Remove plate (4) and trunnion (5).
3. Remove cover (6) and disconnect torque con-

verter oil temperature sensor connector (7) and
torque converter intermediate oil pressure sen-
sor connector (8).
COUPLING
• Carry out coupling in the reverse order to sepa-
ration.
Torque converter assembly mounting bolt:

245 – 308.7 Nm {25 – 31.5 kgm}
Outside of seal ring: Grease (G2-LI)
4. Sling the torque converter and transmission

assembly, then place it with the torque converter
side up.
30-28 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY AND ASSEM-

BLY OF TORQUE CON-
VERTER ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-901-2110 Bracket ■ 1
C 790-901-3011 Plate ■ 1
2 790-101-1871 Nut wrench ■ 1 2) Using 2 forcing screws [1], lift off PTO case
3 792-103-5110 Wrench ■ 1 assembly (10).
★ Before removing the PTO case assem-
bly, make match marks on it.
DISASSEMBLY
1. Set the torque converter assembly to tool C1.
2. Remove control valve assembly (1).
3. Remove torque converter oil temperature sensor

(2) and torque converter intermediate oil pres-
sure sensor (3).
4. Remove elbows (4) and (5) and tube (6).
6. Disassembly of PTO case assembly

1) Using tool C2, remove nuts (9).
2) Remove snap ring (12) and plate (13).
5. PTO case assembly

1) Remove holder (7) and coupling (8).
★ Before removing the holder and coupling,
loosen 3 nuts (9) with tool C2 (Use the
coupling as a stopper).
HD465-7, HD605-7 30-29

➂
3) Press the shaft to remove PTO gear and 9) Remove bushing (25) and outer race (26)
bearing assembly (14). from the PTO case.
★ If the PTO gear and bearing assembly
comes off, bearing (15) comes off, too.
4) Remove inner race spacer (16) and bearing
(17) from the PTO gear.
5) Remove outer races (18) and (19) and outer
race spacer (20) from the PTO case.
★ Since parts (15) – (20) form an assembly,
do not replace any of them with one of
another assembly. (The combination
symbol is stamped on each part.)
7. Turbine and clutch assembly

1) Remove mounting bolts (27) on the pump
side.
2) Remove turbine and clutch assembly (28).
6) Remove snap ring (21).

7) Using forcing screws [2], remove cage (22).
8. Disassembly of turbine and clutch assembly

1) Input shaft
i) Using forcing screws [3], remove input
shaft (29).
ii) Remove bearing (30) from the input
shaft.
8) Remove oil seal (23) and dust seal (24) from

the cage.
30-30 HD465-7, HD605-7

➂
2) Turn over the drive case and remove the 6) Using push tool [4], remove shaft (38) from
mounting bolts and turbine (31). clutch housing assembly (33), then remove
piston (39).
3) Remove drive case (32) from clutch housing

assembly (33). 7) Remove seal rings (40) from piston (39).
4) Remove 2 discs (34) and plate (35).
8) Using push tool [5], remove bearing (41)

5) Turn over the clutch housing and remove from the clutch housing.
snap ring (36) and plate (37). 9) Remove pin (42) and seal ring (43).
HD465-7, HD605-7 30-31

➂
9. Stator assembly
Pull up and remove stator assembly (44).
3) Remove the pump, stator shaft, and rear

10. Disassembly of stator assembly housing assembly from tool C1.
1) Remove stator (45).
4) Remove the mounting bolts and push out
and remove stator shaft (54).
★ At this time, inner race (55) comes off.
2) Remove bushings (47) and (48) and free

wheel (49) from outer race (46).
★ Take care to lose balls (50).
5) Remove seal ring (56), inner race (57), and
sleeve (58) from stator shaft (54).
11. Disassembly of pump, stator shaft, and rear

housing assembly
1) Remove snap ring (51) and inner race (52).
2) Using tool C3, remove nuts (53).
30-32 HD465-7, HD605-7

➂
6) Remove retainer (60) and guide (61) from ASSEMBLY

pump (59).
7) Remove bearing (62) from guide (61). 1. Assembly of pump, stator shaft and rear
housing assembly
1) Install bearing (62) to guide (61) and install
them to pump (59).
★ Bearing (62) is an assembly. Check that
the serial No. and match symbol (A or B)
on its end face are the same as those on
the mating inner race.
2) Install retainer (60) to pump (59).
Retainer mounting bolt:
Adhesive (LT-2)
58.8 – 73.5 Nm {6 – 7.5 kgm}
3) Press fit inner race (57) to stator shaft (54).

★ Inner race (57) is an assembly. Check
that the serial No. and match symbol (A
or B) on its end face are the same as
those on the mating bearing.
4) Fit sleeve (58) and seal ring (57).
★ Fit sleeve (58) by expansion fit.
HD465-7, HD605-7 30-33

➂
5) Install stator shaft assembly (54) to rear

housing (63).
Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
2. Assembly of stator assembly

1) Install free wheel (49) to outer race (46).
★ Install the free wheel with its arrow mark
end on the input side. Check the revolv-
ing direction of the outer race, seeing it
6) Install the stator shaft and rear housing
from the input side.
assembly to tool C1.
Clockwise: Free rotation
7) Install pump assembly (64) and inner race
Counterclockwise: Locked
(55) to stator shaft (54).
Sliding surface:
★ Inner race (55) is an assembly. Check
Engine oil (EO10-CD or EO30-CD)
that the serial No. and match symbol (A
or B) on its end face are the same as
2) Install balls (50) to outer race (46), then
those on the mating bearing.
install bushings (48) and (47) by expansion
fit.
Sliding surface:
8) Using tool C3, tighten nuts (53).

★ Drop about 6 CC of engine oil (EO10-CD
or EO30-CD) over the bearing and rotate
the bearing 10 turns.
Threads of nut: Adhesive (LT-2)
Nut: 441.3 – 490.3 Nm {45 – 50 kgm}
9) Install inner race (52) and snap ring (51).
★ Install the inner race with the wider end
face up.
30-34 HD465-7, HD605-7

➂
3) Install stator (45). 3) Using push tool [6], install bearing (41) to the
Mounting bolt: Adhesive (LT-2) clutch housing.
★ Press fit the bearing until it is stopped by
Mounting bolt:
the clutch housing.
58.8 – 73.5 Nm {6 – 7.5 kgm}
★ Drop about 6 cc of engine oil (EO10-CD
3. Stator assembly
Install stator assembly (44).
4) Install seal ring (40) to piston (39).
★ For the installing direction, see the fol-
lowing figure.
4. Assembly of turbine and clutch assembly

1) Install seal ring (43) to the clutch housing.
★ For the installing direction, see the fol-
lowing figure.
5) Install piston (39) to clutch housing assembly
2) Install pin (42) by expansion fit.
(33).
6) Using push tool [7], press fit shaft (38) to
clutch housing assembly (33).
★ Press fit the shaft until it is stopped by
the bearing.
HD465-7, HD605-7 30-35

➂
7) Install plate (37) to the shaft, then install

snap ring (36).
11) Input shaft

8) Install 2 discs (34) and plate (35).
i) Using push tool [8], install bearing (30).
Sliding surface of disc:
★ Drop about 6 cc of engine oil (EO10-CD
9) Install drive case (32) to clutch housing
assembly (33).
ii) Install input shaft assembly (29) to clutch
★ Watch through holes A (at 6 places on
housing assembly (33).
the periphery) and check that plate (35)
is meshed with the gear of drive case
(32). Mounting bolt:
Mounting bolt: Adhesive (LT-2) 269.7 – 308.9 Nm {27.5 – 31.5 kgm}
Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
5. Turbine and clutch assembly

1) Install turbine and clutch assembly (28).
10) Install turbine (31). 2) Tighten mounting bolts (27) (30 pieces).
Mounting bolt: Adhesive (LT-2) Mounting bolt: Adhesive (LT-2)
Mounting bolt: Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm} 49.0 – 58.8 Nm {5 – 6 kgm}
30-36 HD465-7, HD605-7

➂
6. Assembly of PTO case assembly 3) Fit the O-ring to cage (22) and install them to
1) Press fit outer race (26) and bushing (25) to the PTO case.
the PTO case. 4) Install snap ring (21).
★ After press fitting bushing (25), bend the ★ Install the snap ring so that its closed gap
PTO case end (by 4 points equally will be on the left side (in the direction of
spaced on the periphery) with a punch, 9 o'clock) when it is on the truck and
etc. until it is over the bushing. seen from the engine side.
2) Using push tool [9], install dust seal (24) and 5) Install outer race spacer (20) and outer races
oil seal (23) to cage (22). (18) and (19) to the PTO case.
i) Thinly apply gasket sealant (LG-5) to the 6) Install bearing (17) and inner race spacer
seal fitting surface inside the cage.ii) (16) to the PTO gear.
ii) Install the seals so that the distances 7) Install PTO gear and bearing assembly (14)
from the cage top to their tops will be as to the PTO case, then install bearing (15) to
follows. the shaft.
• Distance a: 23.6 ± 0.2 mm ★ Since parts (20) – (15) form an assembly,
• Distance b: 8.75 ± 0.25 mm do not replace any of them with one of
★ After installing, wipe off the projected another assembly. (The combination
gasket sealant thoroughly. symbol is stamped on each part.)
iii) Fill the space between the oil seal and ★ Apply grease (G2-LI) to the inside spline
dust seal and the space between the lips of the PTO gear shaft.
of the oil seal with silicone grease
(ThreeBond 1855)
★ Supply grease of quantity equivalent
to 40 – 60% of the space between
the lips so that it will not be projected.
HD465-7, HD605-7 30-37

➂
8) Install plate (13) and snap ring (12).

9) Using tool C2, tighten nuts (9) temporarily.
★ Install the nuts with the chamfered side
down.
★ Tighten the nuts permanently after install-
ing the PTO case assembly (since they
will be used to stop the coupling).
Threads of nut: Adhesive (LT-2)
8. Install elbows (5) and tube (6).

★ When installing elbows (5), check that there
are stamps of <2> on their outside.
Elbow: 34.3 – 63.8 Nm {3.5 – 6.5 kgm}
9. Install elbows (4).

Threads of elbow:
7. PTO case assembly Gasket sealant (LG-5)
1) Sling PTO case assembly (10) and fit the O- Elbow: 16.7 – 29.4 Nm {1.7 – 3.0 kgm}
ring. Using guide bolt [10], install the PTO
case assembly. 10. Install torque converter intermediate pressure
★ When installing the PTO case assembly, sensor (3).
match the match marks. Threads of sensor:
Mounting bolt: Gasket sealant (LG-5)
98.1 -– 122.6 Nm {10 – 12.5 kgm} Sensor: 9.8 – 19.6 Nm {1 – 2 kgm}
11. Install torque converter oil temperature sensor

(2).
Threads of sensor:
Sensor: 29.4 – 49.0 Nm {3.0 – 5.0 kgm}
12. Install control valve assembly (1).

Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 Kgm}
2) Install coupling (8) and holder (7).

Mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
3) Using tool C2, tighten the nuts (9) to the fol-
lowing torque which were tightened tempo-
rarily in steps 6-9).
★ Use the coupling as a stopper.
Nut:
392.4 – 441.5 Nm {40 – 45 kgm}
30-38 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY AND ASSEM- 4) Remove cover (7) and lubricating oil temper-
ature sensor (8).
BLY OF TRANSMISSION 5) Remove block (9).
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
D1 799-301-1600 Oil leak tester kit ■ 1
DISASSEMBLY
1. Transmission mount, cover, wiring harness,
and sensors
2. Control valve assembly
1) Remove both transmission mounts (1).
1) Separate the connector of each control valve
2) Remove covers (2) and (3).
and remove wiring harness (10).
2) Install a sling bolt to position A and remove
control valve assembly (11) and valve seat
together.
★ After removing the control valve, cover
the oil holes on the mating face of the
transmission case with tapes, etc. to pre-
vent foreign matter from entering the
transmission case.
3) Remove each control valve (12) and filter
assembly (13) from the valve seat.
3) Remove input shaft speed sensor (4), inter-

mediate shaft speed sensor (5), and output
shaft speed sensor (6).
3. Sleeve
Using a forcing screw, remove 5 sleeves (14).
HD465-7, HD605-7 30-39

➂
4. Oil pan 5. Check of operation of pistons

1) Sling transmission assembly (15) and remove Using tool D1, blow air into the clutch ports and
oil pan (16). check the operation of the pistons of No. 1, 2,
and 3 clutches. (Since you cannot check the
operation of the pistons of No. 2 and 3 clutches
directly, check it by movement of the discs or
plates.)
★ The locations of the clutch ports are shown
below.
• No. 1 clutch port: A
• No. 2 clutch port: B
• No. 3 clutch port: C
★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
• Standard stroke of clutch No. 1 piston:
4.2 mm
6. No. 1 clutch plates

2) Remove cover (17) from the oil pan, then 1) Using sling bolts, remove No. 1 clutch plates
remove spring (18) and magnet assembly (24).
(19). ★ There are 2 bolts installed from the trans-
mission case side.
3) Remove blocks (20) and (21) from the oil

pan, then remove relief valves (22) and (23). 2) Remove bearing (25) from No. 1 clutch plates.
30-40 HD465-7, HD605-7

➂
7. No. 1 clutch spring and guide 10. Input shaft and No. 1 ring gear assembly
Remove spring (26) and guide (27). 1) Sling the input shaft and remove the input
shaft and No. 1 ring gear assembly (33).
8. Discs, plates, and springs
Remove discs (28), plates (29), and spring (30).
2) Pull up remove No. 1 ring gear (34).

3) Remove seal rings (206) and (207) from the
9. No. 1 clutch drum and piston input shaft.
1) Using hanging bolts, remove clutch No. drum
(31) and piston (32) together, then separate
them from each other.
4) Remove inner race (35) from No. 1 ring gear

(34).
2) Remove seal rings (100) and (101) from pis-

ton (32).
HD465-7, HD605-7 30-41

➂
5) Remove snap ring (36) and press down and 11. No. 2 clutch assembly
remove gear (37). Lift of No. 2 clutch assembly (42).
6) Remove inner race (38) from gear (37). 12. Disassembly of No. 2 clutch assembly
1) Turn over No. 2 clutch assembly and remove
housing (43).
7) Remove snap ring (39), then remove input

shaft (41) from bearing (40).
2) Remove mounting bolts, cover (44), and pis-
ton (45).
30-42 HD465-7, HD605-7

➂
3) Remove seal ring (46) from piston (45).
8) Remove plates (59) from carrier (60).

4) Housing assembly
i) Remove seal rings (47) and (48).
ii) Remove snap ring (49), bushing (50),
and ball (205).
★ Take care not to lose ball (205).
iii) Remove inner race (51) and bearing
(52).
9) Carrier assembly
i) Remove shaft (61).
ii) Remove planetary gears (63), thrust
washer (64), and bearing (65).
5) Remove snap ring (53) and ring gear (54).
6) Remove discs (55), plates (56), and spring

(57).
7) Using sling bolts, remove drum (58).
HD465-7, HD605-7 30-43

➂
iii) Remove seal ring (66), inner race (67), and 14. Check of operation of piston
bearing (68) from carrier (60). Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
Standard strokes of pistons
Piston No. Stroke (mm)
4 4.8
5 5.8
6 5.0
7 5.0
13. Transmission case

1) Remove cage assembly mounting bolts (69)
and lift off transmission case (70) vertically.
15. No. 3 clutch housing assembly

Remove the housing mounting bolts and No. 3
clutch housing assembly (75).
★ For disassembly, see Step 12, DISASSEM-
BLY OF NO. 2 CLUTCH ASSEMBLY, 1) - 4).
(No. 3 clutch assembly has the same struc-
2) Remove the following parts from the trans- ture as No. 2 clutch assembly.)
mission case.
i) Remove the assembly of cage (71) and
bearings (72), then remove the bearings
from the cage.
ii) Remove collars (73) and bearings (74)
from the case.
iii) Remove seal ring (204) from the collar.
30-44 HD465-7, HD605-7

➂
16. No. 3 clutch drum, discs, and plates 18. Tie bolts
1) Using hanging bolts, remove No. 3 clutch drum Remove tie bolts (83).
(76), discs, plates, and spring together.
2) Remove discs (77), plates (78), and spring 19. No. 4 clutch plates and sun gear
(79). 1) Remove plates (84).
2) Remove snap ring (85) and sun gear (86).
17. No. 3 clutch ring gear

1) Remove No. 3 clutch ring gear (80).
2) Remove inner race (81) and seal ring (82) 3) Remove seal ring (200) from No. 4 sun gear
from the ring gear. (86).
HD465-7, HD605-7 30-45

➂
20. No. 4 clutch discs, plates, and springs 2) Remove seal rings (93) and (94) from No. 4
Remove discs (87), plates (88) and (101), and housing (91) and piston (92).
springs (89) and (90).
★ Distinguish plates (88) and (101) from each
other.
★ Since springs (90) of a clutch line have a part
No. different from those of another clutch
line, store them for each clutch line.
22. No. 5 clutch discs, plates, and springs

Remove discs (95), plates (96), and springs (97)
and (98).
★ Since springs (97) of a clutch line have a part
No. different from those of another clutch
line, store them for each clutch line.
21. No. 4 housing, piston, and ring gear

1) Using hanging bolts, remove No. 4 housing
(91), piston (92), and ring gear (93) together.
★ If the dowel pin is hard to remove and it
may cuff the housing, take care
extremely.
30-46 HD465-7, HD605-7

➂
23. No. 5 housing, piston, ring gear, and guide 24. No. 6 clutch discs, plates, and springs
pins Remove discs (108), 4 plates (109) and (110),
1) Using sling bolts, remove No. 5 housing (99), and springs (111) and (112).
piston (102), and ring gear (103) together. ★ Since springs (111) of a clutch line have a
★ If the dowel pin is hard to remove and it part No. different from those of another
may cuff the housing, take care clutch line, store them for each clutch line.
extremely. ★ Distinguish plates (109) and (110) from each
2) Remove guide pins (202). other.
3) Remove seal rings (106) and (107) from No.

5 housing (99) and piston (102).
25. No. 4 and No. 5 carriers assembly

Using hanging bolts, remove No. 4 and No. 5
4) Remove sleeve (203) for tie bolt (83) from carriers assembly (201).
No. 5 housing and check the direction of the
sleeve (slit A).
HD465-7, HD605-7 30-47

➂
26. Disassembly of No. 4 and No. 5 carriers assem- 5) Drive out shaft (123) toward No. 4 carrier and
bly remove ball (124).
1) Remove No. 5 sun gear (113). ★ Take care not to lose ball (124).
6) Drive out shaft (123) further and remove it.
7) Remove No. 4 planetary gears (300), bear-
ing (125), thrust washer (126), No. 5 plane-
tary gear (119), bearing (120), collar (121),
and thrust washer (122).
8) Remove snap ring (127) and ring gear (129).
2) Turn over the carrier assembly and remove

bearing (115) and seal ring (116).
3) Drive out shaft (117) toward the ball and

remove ball (118).
★ Take care not to lose the ball.
4) Drive out shaft (117) from the ball side and
remove No. 5 planetary gears (119), bearing 27. No. 6 and No. 7 housings, pistons, and springs
(120), collar (121), and thrust washer (122). 1) Using sling bolts, remove No. 6 and No. 7
★ At this time, 4 of 8 No. 5 planetary gears housings (131) and pistons (132) and (133).
come off. ★ If the dowel pin is hard to remove and it
may cuff the housing, take care extremely.
30-48 HD465-7, HD605-7

➂
2) Remove seal rings (134), (135), and (136) 29. No. 6 and No. 7 carriers assembly
from No. 6 and No. 7 housings and pistons Using sling bolts, sling the shaft and remove No.
(132) and (133). 6 and No. 7 carriers assembly (142).
28. No. 7 clutch discs, plates, and springs 30. Disassembly of No. 6 and No. 7 carriers assem-
Remove discs (138), plates (139), and springs bly
(140) and (141). 1) Remove collar (143).
★ Since springs (141) of a clutch line have a 2) Remove inner race (144) and snap ring (145)
part No. different from those of another from collar (143).
clutch line, store them for each clutch line.
3) Tighten forcing screws [1] to remove plates

(146).
4) Remove seal ring (147) and bearing (148)
from the plates.
HD465-7, HD605-7 30-49

➂
5) Remove intermediate shaft (149) and No. 6

sun gear (150) together.
6) Remove snap ring (151) and inner race (152)
from intermediate shaft (149).
31. Guide pins and No. 7 clutch ring gear

1) Remove guide pins (168).
2) Remove No. 7 clutch ring gear (169).
7) Pull out shaft (153) and remove No. 6 plane-
tary gear (154), bearing (155), thrust washer
(156), and ball (157).
32. Cage assembly

1) Using forcing screws [3], remove cover (172)
from cage assembly (171).
2) Remove seal ring (173) from the cover.
8) After removing No. 6 planetary gear, drive 3) Remove bearing (174) from the cage.
out shaft (158), collar (159), inner race (160),
and ball (161), using drive shafts [2] (14 mm
or less in diameter and about 200 mm in
length).
★ Hit both shafts evenly to drive out the
above parts gradually.
9) Remove seal ring (170) from collar (159).
10) Remove planetary gear No. 7 (162), bearing
(163), and thrust washer (164).
11) Remove snap ring (165), collar (166), and
ball (167).
30-50 HD465-7, HD605-7

➂
33. Output shaft and cage assembly

1) Remove mounting bolts (301) and output 3) Support cage (178) and press the output
shaft and cage assembly (175). shaft (179) with a press to drive it out of the
★ Since the whole transmission is being bearing.
disassembled now, the output shaft and
cage assembly are removed at this time.
You can remove only the output shaft
assembly for repair of a leaking oil seal,
etc., however, if you remove the speed-
ometer gear (optional) in advance.
4) Remove bearing (180) from output shaft

(179).
2) Remove worm (176) and collar (177) from

the output shaft.
★ The collar consists of 2 semicircular
pieces.
5) Remove oil seal (181) and bearing (182)

from cage (178).
HD465-7, HD605-7 30-51

➂
ASSEMBLY 1. Output shaft and cage assembly

1) Install bearing (182) and oil seal (181) to
★ Clean the all parts and check them for dirt or cage (178).
damage before installing. Oil seal lip:
★ Coat the sliding surfaces of each part with Silicone grease (ThreeBond 1855)
engine oil before installing. Press fitting surface on cage side:
★ Soak the discs in clean engine oil (EO-10CD) for Gasket sealant (LG-5)
at least 2 minutes. ★ After press fitting, wipe off the excessive gas-
★ Install each piston seal ring (a) of the clutch ket sealant.
assembly with its pressure receiving side (side
b) directed toward housing (c).
★ Apply grease (G2-LI) to the periphery of the all
seal rings.
★ When fitting a bearing by expansion fit, drop
engine oil (EO10-CD or EO30-CD) over it and
rotate it 10 turns before chilling it in dry ice, etc.
2) Press fit bearing (180) to output shaft (179).
★ Securely fit springs (A) of No. 4 – No. 7clutches

to the seats of the piston and housing.
3) Set output shaft (179) on the press stand and

press the inner race side of the bearing to
install cage (178).
30-52 HD465-7, HD605-7

➂
4) Install collar (177) and worm (176) to the out- 3. Guide pins and No. 7 clutch ring gear
put shaft. 1) Install guide pins (168) to the cage.
★ The collar consists of 2 semicircular 2) Install No. 7 clutch ring gear (169).
pieces.

5) Fit the O-ring to the cage and install output Install discs (138), plates (139), and springs
shaft and cage assembly (175). (140) and (141).
★ Install the 4 discs and 3 plates.
★ Securely fit springs (141) to the seats of the
housing.
2. Cage assembly
1) Using the push tool, press fit bearing (174) to
cage (171).
2) Install cover (172) to cage (171).
Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
3) Install seal ring (173) to cover (172).
Periphery of seal ring:
Grease (G2-LI)
HD465-7, HD605-7 30-53

➂
5. No. 7 clutch piston 7. Assembly of No. 6 and No. 7 carriers assem-

Install seal ring (134) to piston (133), then match- bly
ing it to the springs. 1) Install bearing (163) to No. 7 planetary gear
★ Install the seal ring as shown below. (162). Fit thrust washers (164) to both sides
Periphery of seal ring: Grease (G2-LI) of them and set them to the carrier.
2) Press fit shaft (158) and set ball (161) to
6. No. 6 and No. 7 housings and No. 6 piston secure the shaft.
1) Install seal rings (134), (135), and (136) to ★ When press fitting the shaft, align it with
housing (131) and piston (132). the bearing and avoid hitting it strongly
★ Install the seal rings as shown below. so that the bearing cage will not be
Periphery of seal ring: Grease (G2-LI) deformed.
3) Install seal ring (170) to collar (159) and
press fit inner race (160).
Grease (G2-LI)
4) Install ball (167) and collar (166) to the car-

rier and secure them with snap ring (165).
5) Check that No. 7 planetary gear rotates
smoothly.
6) Install bearing (155) to No. 6 planetary gear

(154). Fit thrust washers (156) to both sides
of them and set them to the carrier.
7) Drive shaft (153) and set ball (157) to secure
the shaft.
2) Using sling bolts, sling No. 6 and No. 7 hous- ★ When driving the shaft, align it with the
ings (131), matching them to piston (133). bearing and avoid hitting it strongly so
★ If the dowel pin is hard, drive it with a that the bearing cage will not be
plastic hammer. deformed.
8) Check that No. 6 planetary gear rotates
smoothly.
30-54 HD465-7, HD605-7

➂
9) Press fit inner race (152) to intermediate 15) Install snap ring (145) to collar (143).
shaft (149). ★ Check that the snap ring is fitted to the
10) Install snap ring (151). collar groove.
★ Check that the snap ring is fitted to the 16) Press fit inner race (116) to collar (115) and
groove. install them to the intermediate shaft.
11) Install No. 6 and No. 7 carrier intermediate
shaft (149) and sun gear (150).

Using sling bolts, sling the shaft. Install No. 6
12) Press fit bearing (148) to plate (146). and No. 7 carriers assembly (142), matching the
★ Securely press fit the bearing to the cor- gear to the bearing.
rect stopper position.
13) Install seal ring (147).
Grease (G2-LI)
14) Install plate (146) to No. 6 and No. 7 carriers.
Mounting bolts: Adhesive (LT-2)
Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
HD465-7, HD605-7 30-55

➂
9. Assembly of No. 4 and No. 5 carriers assembly

1) Install bearing (300) to No. 4 planetary gear
2) Set collar (121) between 2 bearings (120)
and install them to No. 5 planetary gear
3) Chill shaft (123) in dry ice, then install it to
the carrier.
★ Check that the shaft, bearing, thrust
washers, and carrier are aligned and
take care that the bearing and thrust
washers will not be damaged.
★ Match the ball fitting hole of the shaft to
the hole of the carrier. 7) Set collar (121) between 2 bearings (120)
4) Fit ball (124) and install shaft (123) securely. and install them to No. 5 planetary gear
5) Check that the gear rotates smoothly. (119). Fit thrust washers (122) to both sides
6) Install ring gear (129) to the carrier and of them and set them to the carrier.
secure it with snap ring (127). 8) Drive shaft (117), matching the bearing to the
★ Mesh the external teeth on the carrier thrust washer.
side with the internal teeth on the ring 9) Drive out shaft (117) until the ball hole is
gear side, then align the carrier with the seen perfectly, then fit ball (118) and drive
ring gear so that the snap ring will be the shaft into the carrier.
★ When driving the shaft, align it with the
inside the 45° chamfering diameter of the
bearing and avoid hitting it strongly so
ring gear. that the bearing cage will not be
★ Check that the external teeth are deformed.
meshed with the internal teeth and the ★ Check that the gear rotates smoothly.
whole snap ring is inside the chamfering
diameter of the ring gear, then press in
the ring gear until it is locked.
★ Check that the clearance between the
bottom of the external teeth of the carrier
and the inside diameter of the fitted snap
ring is 2.0 – 3.2 mm through the circum-
ference.
★ Hold the ring gear and move it up and
down. Check that carrier does not come
off at this time.
10) Install bearing (115) and seal ring (116) to the

carrier assembly.
Grease (G2-LI)
30-56 HD465-7, HD605-7

➂

Using hanging bolts, sling the shaft. Install No. 4 2) Install gear (86).
and No. 5 carriers assembly (201), matching the 3) Install snap ring (85).
gear to the bearing.
★ You can install the "No. 4, No. 5 carriers, No.
6, and No. 7 assembly", too, as you
removed. If this assembly is slung and
moved, however, the bearing in the interme-
diate position may come off. Accordingly,
divide this assembly.

Install plate (110), discs (108), plates (109), and
★ Install the 4 discs, 4 plates (109), and 1 plate
(110).
★ Install one of plates (109) on the top.
11. No. 5 clutch sun gear ★ Check that springs (111) are fitted to the
Install sun gear (113). seats of the piston and housing.
★ Take care not to have your fingers caught in ★ Securely install 6 springs (112) to each disc.
the gears.
12. No. 4 clutch sun gear

1) Install seal ring (200) to gear (86).
Grease (G2-LI)
HD465-7, HD605-7 30-57

➂
14. No. 5 housing, piston, ring gear, and guide

pins
1) Install tie bolt sleeves (203) to No. 5 housing
(99).
★ When installing the sleeve, set slit A at
the position checked when removed.
★ When tie bolts (83) are installed, they
become hard because of the cushion
sleeves. At this time, do not drive them
forcibly with a hammer. (For prevention
of breakage)
15. No. 5 clutch, discs, plate, and springs

Install discs (95), plate (96), and springs (97) and
(98).
★ Install the 5 discs and 4 plate.
★ Securely install 6 springs (98) to each disc.
2) Install seal rings (106) and (107) to housing

(99) and piston (102), then install the piston
to the housing.
★ Install the seal ring as shown in the fol-
lowing figure.
Grease (G2-LI)
3) Set No. 5 clutch ring gear (103).

★ Set the gear with the chamfered side up.
4) Using hanging bolts, install No. 5 housing
(99), matching it to the spring.
★ If the dowel pin is hard, drive it with a
plastic hammer.
5) Install guide pins (202).
30-58 HD465-7, HD605-7

➂
16. No. 4 housing, piston, and ring gear

1) Install seal rings (93) and (94) to housing
(91) and piston (92), then install the piston to
the housing.
★ Install the seal rings as shown below.
Grease (G2-LI)
2) Using sling bolts, install No. 4 housing,

matching it to the spring.
★ Check that the springs are fitted to the
seats of the piston and plate.
★ If the dowel pin is hard, drive it with a
plastic hammer.
3) Install ring gear (93).
★ Set the gear with the chamfered side up.
18. No. 4 clutch plate

Install plate (84).
★ Check that the springs are fitted to the seats
of the piston and plate.
19. Tie bolts

Install tie bolts (83).
★ Press in each bolt to the end of the cup hole.
Do not use a hammer at this time.
★ Do not use an impact wrench until the bolt
catches the threads.
Tie bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
17. No. 4 clutch, discs, plate, and springs
Install plate (101), discs (87), plates (88), and
★ Install the 4 discs, 3 plates (88), and 1 plate
(101).
★ Securely install 6 springs (89) to each disc.
HD465-7, HD605-7 30-59

➂
20. No. 3 clutch ring gear

1) Install inner race (81) and seal ring (82) to
the ring gear.
Grease (G2-LI)
22. Check of operation of piston

Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
2) Install No. 3 clutch ring gear (80). ★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
Mounting bolt: Adhesive (LT-2) Standard stroke of piston
Mounting bolt:
156.9 – 196 Nm {16 – 20 kgm} Piston No. Stroke (mm)
4 4.8
5 5.8
6 5.0
7 5.0
★ If the pistons do not move smoothly, apply

engine oil to them.
21. No. 3 clutch housing assembly

★ For disassembly, see Step 24, DISASSEM-
BLY OF No. 2 CLUTCH ASSEMBLY, 5) – 8).
(No. 3 clutch assembly has the same struc-
ture as No. 2 clutch assembly.)
★ The plates, discs, and springs are 1 each
less than those of No. 2 clutch assembly.
★ Using hanging bolts, sling and install housing
assembly (75), matching the internal teeth of
23. Transmission case
the disc to the external teeth of the ring gear.
1) Install the following parts to the transmission
Mounting bolt: Adhesive (LT-2) case.
Mounting bolt: i) Install seal ring (204) to the outer groove
98 – 122.5 Nm {10 – 12.5 kgm} of collars (73), then install them, match-
ing to the dowel pin of the transmission
case.
Grease (G2-LI)
ii) Install cage (71).
iii) Install bearings (72) and (74) to both
sides.
★ Press fit the bearings until they are
stopped by collars (73).
30-60 HD465-7, HD605-7

➂
★ When driving the shaft, align it with

th e b ear in g a nd av oid hi tti ng it
strongly so that the bearing cage will
not be deformed.
iv) Fit ball (64) and install shaft (61) securely.
★ If the shaft moves out, caulk the car-
rier side with a punch.
★ Check that the gear rotates smoothly.
2) Install the O-ring to the transmission case.

3) Sling and install transmission case (70) and
tighten cage assembly mounting bolts (69).
2) Install plate (59) to carrier (60).

Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
24. Assembly of No. 2 clutch assembly

1) Carrier assembly
i) Install inner race (67), bearing (68), and
seal ring (66) to carrier (60).
Grease (G2-LI)
3) Turn over the carrier assembly. Using sling

bolts, install drum (58), matching it to the
gear of the carrier.
ii) Install bearing (65) to gear (63). Fit thrust

washers (64) to both sides of them and
set them to the carrier.
iii) Matching the thrust washer to the bear-
ing, drive shaft (61).
HD465-7, HD605-7 30-61

➂
4) Install the ring gear (54), matching it to the 8) Install piston (45) to the housing, then install
carrier, and secure it with snap ring (53). cover (44).
5) Discs, plates, and springs Mounting bolt: Adhesive (LT-2)
Install discs (55), plates (56), and springs
Mounting bolt:
(57) between the drum and ring gear.
★ Install the 5 discs, 4 plates, and 5 58.8 – 73.5 Nm {6 – 7.5 kgm}
springs.
9) Install housing (43) to the drum.

6) Housing assembly
i) Install inner race (51) and bearing (52) to Mounting bolt: Adhesive (LT-2)
the housing. Mounting bolt:
ii) Install ball (205) and bushing (50), then 98 – 122.5 Nm {10 – 12.5 kgm}
secure them with snap ring (49).
iii) Install seal rings (47) and (48).
Grease (G2-LI)
25. No. 2 clutch assembly

Using sling bolts, sling and install No. 2 clutch
assembly (42), matching the external teeth of the
piston to the internal teeth of the drum.
7) Install seal ring (46) to piston (45).
★ Install the seal ring as shown below.
Grease (G2-LI)
30-62 HD465-7, HD605-7

➂
26. Input shaft and No. 1 ring gear assembly 4) Install inner race (35) to No. 1 ring gear (34).
1) Press fit bearing (40) to input shaft (41) and
install snap ring (39).
5) Install ring gear (34) and seal rings (206) and

(207) to the input shaft.
2) Install inner race (38) to gear (37). Periphery of seal ring:
Grease (G2-LI)
3) Install gear (37) to the outer race side of the

bearing, then install snap ring (36). 6) Sling the input shaft and install the input
shaft and No. 1 ring gear assembly (33),
matching the gear to the bearing.
HD465-7, HD605-7 30-63

➂
27. No. 1 clutch, drum, and piston 29. No. 1 clutch plate
1) Install seal rings (100) and (101) to piston 1) Install bearing (25) to No. 1 clutch plate.
(32), then install them to the drum (31).
Grease (G2-LI)
2) Using sling bolts, install No. 1 clutch drum
(31) and piston (32) together.
2) Using sling bolts, install plate (24), matching

it to the spring and guide.
Mounting bolt:
156.9 -– 196 Nm {16 – 20 kgm}
30. Check of operation of piston

Using tool D1, blow air into the clutch ports and
check the operation of the pistons of No. 1, 2, and
3 clutches. (Since you cannot check the opera-
28. No. 1 clutch discs, plates, and springs tion of the pistons of No. 2 and 3 clutches directly,
Install discs (28), plates (29), springs (26) and check it by movement of the discs or plates.)
(30), and guide (27). ★ The locations of the clutch ports are shown
★ Install the 3 discs and 2 plates. below.
• No. 1 clutch port: A
• No. 2 clutch port: B
• No. 3 clutch port: C
• Standard stroke of clutch No. 1 piston
4.2 mm
30-64 HD465-7, HD605-7

➂
31. Oil pan 32. Sleeve

1) Install relief valves (22) and (23) to the oil Fit the O-rings to sleeves (14) and install them to
pan, then install blocks (20) and (21). the transmission.
2) Install magnet assembly (19) and spring (18)

to the oil pan, then fit the O-ring and install 33. Control valve assembly
cover (17). 1) Install each control valve (12) to the valve
seat.
Control valve:
8.0 – 10.0 Nm {0.8 – 1.0 kgm}
2) Install filter assembly (13).
★ If the filter case and filter bracket plug
were removed, tighten them to the fol-
lowing torque.
Filter case:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
Plug:
15.7 – 19.2 Nm {1.6 – 2.0 kgm}
3) Install sling bolts to A, then install the valve
seats and control valve assembly (11)
together.
3) Fit the plate gasket to oil pan (16) horizon- Mounting bolt:
tally, then sling and install transmission Gasket sealant (LG-5)
assembly (15). 4) Install wiring harness (10) and connect the
Both sides of plate gasket: connectors to each control valve.
HD465-7, HD605-7 30-65

➂
34. Sensors, wiring harness, covers, and trans-

mission mounts
1) Install block (9).
2) Install lubricating oil temperature sensor (8)
and cover (7).
3) Install output shaft speed sensor (6), inter-

mediate shaft speed sensor (5), and input
shaft speed sensor (4).
★ For installation procedure, see TESTING
AND ADJUSTING, Adjusting transmis-
sion speed sensors.
4) Install covers (2) and (3).

5) Install both transmission mounts (1).
30-66 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL AND INSTALLA- 5. Remove guard (3) and drive shaft (4).
TION OF DIFFERENTIAL 6. Disconnect hoses (5), (6), and (7) and remove
ASSEMBLY slack adjuster (8).
REMOVAL
Apply the parking brake and put blocks under

the wheels.
1. Remove the dump body assembly. For details,

see REMOVAL AND INSTALLATION OF DUMP
BODY ASSEMBLY".
2. Drain oil from the differential case and final drive

case.
Differential case: 95
Final drive case (Each side): 21 7. Using forcing screws [2] and guide bolt [3], pull
3. Using guide bolts [1], remove cover (1). (The out differential assembly (9) forward.
rear wheel assembly is removed in the following Differential assembly: 850 kg
photo. It does not need to be removed, how-
ever.)
4. Pull out drive shaft (2).

★ Install a hanging bolt to the shaft end to pull
out the shaft.
Drive shaft: 110 kg
HD465-7, HD605-7 30-67

➂
INSTALLATION
removal.
Drain plug
(Center of cover on final drive case side):
127.4 – 176.4 Nm {13.0 – 17.9 kgm}
(Periphery of cover on final drive case side):
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
★ Before tightening the bolts, check that the

key way of the spider cap is fitted to the key
way of the mating yoke.
Mounting bolt:
157 – 196 Nm {16.0 – 19.9 kgm}
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
Refilling with oil

Differential case: 95 (EO30-CD)
Final drive case (Each side):

21 (EO30-CD)
30-68 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEM- 4. Bevel pinion and cage assembly

1) Lift off bevel pinion and cage assembly (5).
BLY OF DIFFERENTIAL ★ Before removing the bevel pinion and
ASSEMBLY cage assembly, make match marks on
the cage and differential case.
Special tools ★ Check the thickness, quantity, and loca-
tion of shim (6).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-901-5110 Bracket ■ 1
790-901-3420 Plate ■ 1
H
2 790-425-1660 Wrench ■ 1
3 790-102-1130 Power wrench assembly ■ 1
4 797-101-1171 Wrench ■ 1
DISASSEMBLY
1. Tool of differential assembly
Set the differential assembly to tool H1. 2) Using press [2], press down bevel pinion
assembly (7) and remove it and bearing (8)
2. Coupling together from cage assembly (9).
Remove holder (1) and coupling (2). ★ Set a block, etc. under the bevel pinion
assembly to prevent the assembly from
falling to the floor.
3. Cage
1) Using forcing screws [1], remove cage (3).
★ Before removing the cage, make match
marks on it and differential case.
2) Remove oil seal (4) from cage (3).
HD465-7, HD605-7 30-69

➂
3) Disassembly of bevel pinion assembly

Remove spacer (11) and bearing (12) from
bevel pinion assembly (10).
4) Disassembly of cage assembly

Remove outer races (14) and (15) from cage
(13).
4) Sling differential gear assembly (20) tempo-

rarily.
5) Using tool H3, remove 4 bearing cap bolts
(21).
6) Remove bearing caps (22) and (23) and
adjustment nuts (18) and (19).
5. Removal of differential gear assembly

1) Turn over tool H1.
2) Remove locks (16) and (17).
3) Using tool H2, loosen adjustment nuts (18)
and (19) until you can turn them with the
hand.
30-70 HD465-7, HD605-7

➂
7) Remove outer races (24) and (25) from both 3) Remove bearing (29) from case (27).
bearings and lift off differential gear assem-
bly (20).
4) Remove side gear (30).
6. Disassembly of differential gear assembly

1) Lift off case and bearing assembly (26).
★ Before removing the assembly, make
match marks on the top and bottom of
the case.
5) Remove cross shaft and pinion gear assem-

bly (31).
2) Remove washer (28) from inside of case

(27).
HD465-7, HD605-7 30-71

➂
6) Remove pinion gear assembly (33) from 10) Remove washer (38).
cross shaft (32).
11) Turn over the case and bevel gear assembly.

7) Using tool H4, remove nut (34).
8) Remove sleeve (35) and the bearing. 12) Remove bevel gear (39) from case (40).
★ The bearing is an assembly of large ★ Before removing the bevel gear, make
bearing A, small bearing B, outer race match marks on it and the case.
spacer C, and inner race spacer D. 13) Remove bearing (41).
9) Remove side gear (37).
30-72 HD465-7, HD605-7

➂
ASSEMBLY ★ After installing the washer, check that

distance a between the washer surface
★ Clean the all parts and check them for dirt or and the end of dowel pin E is 0.35 – 0.75
damage. mm. (If the dowel pin has been
★ Coat the sliding surfaces with engine oil (EO30- removed, drive it to the above dimen-
CD) before installing. sion.)
1. Assembly of differential gear assembly

1) Install bearing (41) to case (40) by shrink fit.
★ Shrink fit temperature of bearing: Keep at
120°C for 30 min.
★ After installing the bearing, drop engine
oil (EO30-CD) over it.
2) Install bevel gear (39) to case (40).
★ When installing, match the match marks.
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
5) Install side gear (37).
3) Turn over the case and bevel gear assembly.

4) Install washer (38).
★ Install the washer with the grooved side
up.
HD465-7, HD605-7 30-73

➂
6) Install the bearing to the pinion gear. 10) Install cross shaft and pinion gear assembly
★ Drop engine oil (EO30-CD) over the slid- (31).
ing parts.
★ The bearing is an assembly of large
bearing A, small bearing B, outer race
spacer C, and inner race spacer D.
★ Do not change the combination of the
above parts. (The same combination
mark is stamped on each part.)
7) Install sleeve (35) as shown in the following
figure.
8) Using tool H4, tighten nut (34).
Nut:
490 – 408 Nm {50.0 – 61.9 kgm}
★ After tightening the nut, rotate the bear-
ing 5 turns or more to check that it
rotates lightly. 11) Install side gear (30).
9) Install pinion gear assembly (33) to cross 12) Install bearing (29) to case (27) by shrink fit.
shaft (32). ★ Shrink fit temperature of bearing: Keep at
120°C for 30 min.
★ After installing the bearing, drop engine
oil (EO30-CD) over it.
30-74 HD465-7, HD605-7

➂
13) Turn over case (27) and install washer (28). 2. Installation of differential gear assembly
★ Install the washer with the grooved side 1) Sling differential gear assembly (20) to the
up. installation position of the differential case.
★ Keep the differential gear assembly
above the differential case.
2) Install outer races (24) and (25) to both bear-
ings.
★ Drop sufficient amount of engine oil
(EO30-CD) over the bearings.
3) Install adjustment nuts (18) and (19) to the
differential case temporarily.
★ After installing the washer, check that

distance a between the washer surface
and the end of dowel pin E is 0.35 - 0.75
mm. (If the dowel pin has been
removed, drive it to the above dimen-
sion.)
4) Install bearing caps (22) and (23).

5) Using tool H3, tighten 4 bearing cap bolts
(21).
★ Before tightening the bearing cap bolts,
rotate the bevel gear 20 - 30 turns to fit
the bearing.
Mounting bolt:
2,450 – 3,040 Nm {249.9 – 309.9 kgm}
★ Before installing the locks for fixing the
adjustment nuts, finish the following
"Adjusting preload on bearing", "Adjust-
14) Sling and install case and bearing assembly ing backlash", "Testing tooth contact",
(26). and "Adjusting tooth contact".
HD465-7, HD605-7 30-75

➂
4. Bevel pinion and cage assembly

1) Assembly of cage assembly
Install outer races (14) and (15) to cage (13).
★ Press fit the outer races until they are
stopped by the cage.
3. Adjusting preload on bearing

Press push-pull scale [3] against the periphery of
bevel gear (39) and measure the starting tangen-
tial force in the tangential direction.
• Standard starting tangential force: 2) Assembly of bevel pinion assembly
39.2 – 62.8 N {4.0 – 6.4 kg} i) Install bearing (12) to bevel pinion (10)
[Target: 51.0 N {5.2 kg}] by shrink fit or press fit it to the end with
★ If the starting tangential force is below the the push tool.
standard value, tighten the adjustment nuts ★ Shrink fit temperature of bearing: Keep at
on both sides with tool H2. If the former 120°C for 30 min.
exceeds the standard value, loosen the ★ After installing the bearing, drop engine
adjustment nuts on both sides. oil (EO30-CD) over it.
★ When adjusting, rotate the bevel gear so that ii) Install spacer (11).
the bearings will be fitted sufficiently. Reference: This spacer is a part of cage
assembly (13) shown above.
30-76 HD465-7, HD605-7

➂
3) Place cage assembly (9) on bevel pinion 5. Cage

assembly (7). 1) Install oil seal (4) to cage (3).
4) Install bearing (8). ★ Press fit the oil seal until it is stopped by
5) Using push tool [4] and revolving cage the cage.
assembly (9), press fit bearing (8) to the end. Outer ring of oil seal:
★ Drop engine oil (EO30-CD) over bearing SEALEND 242 or equivalent
(8). Lip of oil seal: Grease (G2-LI)
★ Do not use a press to press fit the bear- 2) Fit the O-ring and cage (3).
ing. ★ When installing, match the match marks.
6) Hold bevel pinion assembly (7) and revolve Mounting bolt:
cage assembly (9) with the push-pull scale 455 – 565 Nm {46.4 – 57.6 kgm}
and measure the starting tangential force in
the tangential direction.
• Standard starting tangential force:
Max. 24.5 N {2.5 kg}
★ If the starting tangential force exceeds
the standard value, replace bearings (8)
and (12) or cage assembly (9) and mea-
sure again. Check that the starting tan-
gential force is in the standard range.
3) Set dial gauge [5] on the top of bevel pinion

assembly (7). Move the bevel pinion assem-
bly in the thrusting direction and measure the
end play.
• Standard end play: 0 – 0.15 mm
★ If the end play exceeds the standard
value, replace bearings (8) and (12) or
cage assembly (9) and measure again.
Check that the end play is in the stan-
7) Install shim (6) of the thickness and quantity dard range.
checked when disassembled. Fit the O-ring
and sling and install bevel pinion cage
assembly (5).
• Thicknesses of shims:
0.2 mm, 0.3 mm, 1.0 mm
HD465-7, HD605-7 30-77

➂
6. Coupling 3) If the backlash is out of the standard range,

1) Install coupling (2), O-ring, and holder (1). adjust it by moving the bevel gear.
★ Rotate the bevel gear to rotate the bevel ★ Move the bevel gear with tool H2 and
pinion 20 – 30 turns and tighten the adjustment nuts (18) and (19).
mounting bolts gradually. ★ If either adjustment nut is tightened
Mounting bolt: Adhesive (LT-2) (loosened), loosen (tighten) the other
adjustment nut by the same angle so that
Mounting bolt:
the preload applied to bearings (29) and
1,520 – 1,910 Nm {155.0 – 194.7 kgm}
(41) (in Step 3) will not change.
2) Rotate the coupling 20 – 30 turns, and then
check that the holder mounting bolts are
tightened to the specified torque.
7. Adjusting backlash
1) Apply the probe of dial gauge [5] to a tooth
tip of the bevel gear at right angles.
2) Fix the bevel pinion and move the bevel gear
forward and backward (in the revolving direc-
tions) and read the dial gauge.
• Standard backlash: 0.41 – 0.56 mm
★ Measure the backlash at 3 – 4 places
and check that the difference between
the measured values is 0.1 mm or less.
30-78 HD465-7, HD605-7

➂
• When the backlash is below standard 9. Adjusting tooth contact

value If the tooth contact pattern is not proper, adjust
Loosen adjustment nut (19) on the bevel the tooth contact according to the procedure
gear side and tighten adjustment nut (18) on shown in the following page.
the right side by the same angle (to move the ★ Adjust the toot contact by increasing or
bevel gear in the direction of A). decreasing shim (6) (to move the bevel pin-
• When the backlash is above standard ion) and revolving the adjustment nuts (to
value move the bevel gear: See Adjusting back-
Loosen adjustment nut (18) on the right side lash).
and tighten adjustment nut (19) on the bevel ★ After adjusting the tooth contact, check the
gear side by the same angle (to move the backlash again.
bevel gear in the direction of B).
8. Testing tooth contact

Apply red lead thinly to the surfaces of 7 – 8
teeth of the bevel gear and turn the bevel gear in
the forward and reverse directions, then check
the tooth contact pattern on the bevel gear.
★ The center of the tooth contact must be as
follows.
• Middle of tooth height
• Point on tooth at distance of x from small
end C
(x = 46 ± 6 mm)
★ Width y of the tooth contact must be 41 – 82
mm.
★ Check that there is not a strong contact at tip
A, bottom B, small end C, or large end D.
HD465-7, HD605-7 30-79

➂
Tooth contact Cause Adjusting method
Bevel pinion is too far 1. Reduce shim (6) to move bevel

from bevel gear. pinion close to bevel gear.
2. Move bevel gear away from
bevel pinion.
Bevel pinion is too 1. Increase shim (6) to move bevel

close to bevel gear. pinion away from bevel gear.
2. Move bevel gear close to bevel
pinion.
Bevel gear is too close 1. Reduce shim (6) to move bevel

to bevel pinion. pinion close to bevel gear.
2. Move bevel gear away from
bevel pinion.
Bevel gear is too far 1. Increase shim (6) to move bevel

from bevel pinion. pinion away from bevel gear.
2. Move bevel gear close to bevel
pinion.
10. Locks
Install locks (17) and (16) of the adjustment nuts.
30-80 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL AND INSTALLA- 4. Remove wheel assembly (3) with a forklift, etc.
TION OF FRONT WHEEL Wheel assembly: 1,000 kg

ASSEMBLY Rest the removed wheel assembly against
a safe place and put blocks under it to pre-
REMOVAL vent it from falling down.
★ Take care not to break the air valves.
the rear wheels with blocks.
1. Set a hydraulic jack (50 t) under arm (1) and

raise the front wheel assembly.
INSTALLATION
removal.
2. Support the frame on a stand, etc.
★ Tighten the hub nuts evenly in the diagonal

order.
★ Tighten the hub nuts permanently after low-
ering the truck body.
Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
★ After installing the wheel assembly, drive the
truck about 5 - 6 km, then check that the hub
nuts are tightened to the specified torque.
3. Remove hub nuts (2).
HD465-7, HD605-7 30-81

➂
DISASSEMBLY AND ASSEMBLY REAR WHEEL

TION OF REAR WHEEL
ASSEMBLY
REMOVAL

the front wheels with blocks.
1. Set a hydraulic jack (50 t) under either rear axle

and raise the rear wheel assembly.
5. Remove inner hub nuts (4).
2. Loosen the locknut of the air valve and remove

lock plate (1).
3. Remove outer hub nuts (2). 6. Remove wheel assembly (5) with a forklift, etc.
Wheel assembly: 850 kg
Rest the removed wheel assembly against
vent it from falling down.
4. Remove wheel assembly (3) with a forklift, etc.

Wheel assembly: 850 kg
Rest the removed wheel assembly against
vent it from falling down.
30-82 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY REAR WHEEL
INSTALLATION
removal.
,
★ Tighten the hub nuts evenly in the diagonal
order.
★ Tighten the hub nuts permanently after low-
ering the truck body.
Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
★ After installing the wheel assembly, drive the
truck about 5 - 6 km, then check that the hub
nuts are tightened to the specified torque.
HD465-7, HD605-7 30-83

➂
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER PADS
REMOVAL AND INSTALLATION

INSTALLATION OF FRONT • Carry out installation in the reverse order to
BRAKE CALIPER PADS removal.
REMOVAL
★ Push in the torque pin and fix it with the bolt
1. Remove the front wheel assembly. For details, securely.
see REMOVAL, INSTALLATION OF FRONT ★ Adjust the clearance between the pin and
WHEEL ASSEMBLY. disc to 1.5 – 3 mm.
Pin fixing bolt:
2. Pull out torque pin (1). 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
★ Pin fixing bolt (2) and pull out pin (1) to a ★ For precautions for installing the pin fixing
degree that you can remove the pads. bolt, see DISASSEMBLY, ASSEMBLY OF
FRONT BRAKE CALIPERS ASSEMBLY.
★ Bleed air from the front brake circuit. For
details, see TESTING AND ADJUSTING,
Bleeding air from brake circuit.
3. Remove pads (3).

1) Install a vinyl hose to bleeder screw (4) so
that the brake oil will be drained.
2) Loosen the bleeder screw and return pistons
(5) with a bar to the bottoms of the cylinders.
30-84 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPERS

TION OF FRONT BRAKE CALI- • Carry out installation in the reverse order to
PERS ASSEMBLY removal.
REMOVAL
1. Remove the front wheel assembly. For details, Mounting bolt:
see REMOVAL, INSTALLATION OF FRONT 785 – 980 Nm {80.1 – 100 kgm}
WHEEL ASSEMBLY.
★ Bleed air from the front brake circuit. For
2. Disconnect hose (1). details, see TESTING AND ADJUSTING,
Bleeding air from brake circuit.
3. Sling the calipers assembly temporarily and
remove bolts (2).
4. Remove calipers assembly (3).

★ Sling the calipers assembly, adjusting it with
a lever block, etc.
Calipers assembly: 75 kg
HD465-7, HD605-7 30-85

➂
DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF FRONT
BRAKE CALIPERS
ASSEMBLY
DISASSEMBLY
1. Pin fixing bolts (1) and (2) and remove torque
pins (3), (4), and (5) and pads (6).
2. Remove plate (7), plug (8), backup ring (9), and

seal (10).
3. Remove dust seal (11) and piston (12).
4. Remove seal (13) and backup ring (14).

★ Disassemble the other pistons similarly.
1. Fit backup ring (14), seal (13), and dust seal (11)
to the grooves of torque plate (15).
2. Install piston (12).

★ Fit the dust seal lip to the groove of the pis-
ton.
3. Install seal (10), backup ring (9), plug (8), and

plate (7).
4. Install pads (6) and torque pins (5), (4), and (3)
and tighten pin fixing bolts (2) and (1).
Bolt: 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
★ Unlike a usual bolt, each of the above bolts
has pointed end (part "a"). The pointed end
bites in the surface of torque pin (5) (deforms
the pin plastically) (Bitten part: "b", Trace of
biting: "c) to fix the pin. (The bolt must be
tightened further after resistance is felt.)
Accordingly, if the bolt is not tightened to the
specified torque, it cannot bite in and fix the
pin sufficiently.
★ Move the pin in the axial direction, tightening
the pin fixing bolts, check that the bolts are
fitted in the grooves of the torque pin.
30-86 HD465-7, HD605-7

➃
★ Be sure to install torque pin (4), (5) which is

shorter than torque pin (5) to the plate side.
★ Assemble the other pistons similarly.
★ Adjust clearance "d" between disc plate (7)
and torque pin (3) to 1.5 – 3.0 mm.
5. Install the front brake calipers assembly. For

details, see REMOVAL, INSTALLATION OF
FRONT BRAKE CALIPERS.
★ Install the front brake calipers assembly so
that clearance "d" between disc plate (16)
and torque pin (3) will be 1.5 to 3.0 mm.
HD465-7, HD605-7 30-87

➃
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB

BLY OF FRONT WHEEL HUB
ASSEMBLY
DISASSEMBLY
1. Front brake calipers assembly
Remove the front brake calipers assembly. For
2. Cover
Remove cover (1).
3. Wheel hub assembly

1) Support wheel hub assembly (2) with a fork- 5) Disassemble wheel hub assembly according
lift. to the following procedure.
2) Remove retainer (3). i) Remove the mounting bolts and brake
★ Check the quantity of the shims and disc (5).
store them. ii) Remove oil seal (6).
iii) Remove outer race (7).
iv) Remove outer race (8).
4. Bearing and retainer

1) Remove bearing (10).
2) Remove retainer (11).
3) Slant wheel hub assembly (2) lightly from the

rear and press it and bearing (4) out
together.
4) Remove bearing (4) and wheel hub assem-
bly (2).
Wheel hub assembly: 330 kg
30-88 HD465-7, HD605-7

➂
ASSEMBLY
1. Retainer and bearing
1) Install retainer (11).
2) Install bearing (10).
iv) Set brake disc (5) and tighten the mount-

ing bolts.
2) Support and install wheel hub assembly (2)
2. Wheel hub assembly with a forklift.
1) Assemble the wheel hub assembly accord-
ing to the following procedure.
i) Using the push tool, press fit outer race
(8).
ii) Using the push tool, press fit outer race
(7).
iii) Using the push tool, press fit oil seal (6).
★ Degrease the sealing side of wheel hub
A and periphery of the seal.
★ Degrease part B.
Periphery of seal:
Adhesive: (Loctite No. 648)
Space c of seal lip:
Fill with grease (See Table 1).
Fill the shaded parts in the following
Table 1 figure with sufficient amount of
No. Manufacturer Brand of grease grease. (Grease: 9 for each wheel
hub assembly)
1 NIHON KOYU HIREX HD-2
★ Take care not to damage the oil seal on
2 SHELL OIL Super Duty Grease 2 the inside of the hub.
3 ESSO OIL RONEX MP ★ Select the grease from Table 1.
4 BP Energrease LS-EP2
Table 1
No. Manufacturer Brand of grease
1 NIHON KOYU HIREX HD-2
2 SHELL OIL Super Duty Grease 2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
HD465-7, HD605-7 30-89

➂
★ Fill the hatched space between the roll-

ers of the bearing until it is projected from
the opposite side of the retainer.
5) Install the shims and retainer (3). Revolving

the hub 20 – 30 turns, tighten the bolts
evenly to the specified torque..
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
★ After tightening the bolts, rotate the hub
and check that it rotates normally.
4) Adjust the preload on the bearing according

i) Install retainer (3) without inserting any
shim with 3 mounting bolts. Revolving 3. Cover
the hub 20 – 30 turns, tighten the bolts Fit the O-ring and install cover (1).
evenly to the specified torque. Fill the inside of cover (hatched part)
Mounting bolt (For adjustment): with grease.
103 – 113 Nm {10.5 – 11.5 kgm} ★ Use grease of the brand used for the wheel
ii) Measure distance c between the retainer hub in 2-2).
and axle end with depth micrometer [1].
★ Measure at 2 places and obtain the
average.
iii) Remove retainer (3) and measure its
thickness T. Add 0.3 mm to the differ-
ence between above distance c and
thickness d (c – T), then use the result as
the shim thickness.
★ Measure at 2 places and obtain the
average.
★ Combine the shims so that their
quantity will be minimum.
★ When removing the retainer, take
care that the bearing will not come
off. 4. Front brake calipers assembly
Install the front brake calipers assembly. For
30-90 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
REMOVAL AND INSTALLA- 5. Using guide bolts [2] and forcing screws [3], pull
out and remove carrier assembly (6).
TION OF FINAL DRIVE CAR- ★ When the carrier assembly comes off the
RIER ASSEMBLY guide bolts, it is unbalanced suddenly.
Accordingly, insert a bar in the center shaft
REMOVAL hole to balance the carrier assembly.
• The rear wheel assembly is removed in the fol- Carrier assembly: 220 kg
lowing photo. It does not need to be removed,
however.
1. Remove the drain plug of the cover and drain oil

from the final drive case.
Final drive case: 32 (Each side)
2. Using guide bolts [1], remove cover (1).
INSTALLATION
removal.
Drain plug
(Center of cover on final drive case side):
3. Pull out drive shaft (2). 127.4 – 176.4 Nm {13.0 – 17.9 kgm}
★ Install a sling bolt to the shaft end to pull out (Periphery of cover on final drive case side):
the shaft. 24.5 – 34.3 Nm {2.5 – 3.4 kgm}
Drive shaft: 110 kg
4. Remove snap ring (3), sun gear (4), and spacer

Carrier assembly mounting bolt:
(5).
455 – 565 Nm {46.4 – 57.6 kgm}
Final drive case (Each side):

32 (EO30-CD)
HD465-7, HD605-7 30-91

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
DISASSEMBLY AND ASSEM- ASSEMBLY

BLY OF FINAL DRIVE CAR- 1. Install bearing (4) to planetary gear (3).
RIER ASSEMBLY
2. Set planetary gear (3) to the case.
★ Securely match the planetary gear to the
DISASSEMBLY
hose on the case side.
1. Drive out shaft (1) by hitting it outward.
★ Take care not to lose ball (2). 3. Matching the ball hole of shaft (1) to the cut for
the ball on the case side, press fit the shaft until
2. Remove planetary gear (3) and bearing (4). the ball hole comes in contact with the case end.
4. Install ball (2) and press fit shaft (1) to the end.
30-92 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE AND REAR BRAKE
REMOVAL AND INSTALLA- ★ Fix outer gear (5) and wheel hub (6) at fol-
lowing points a, b, c and d (4 points in total).
TION OF FINAL DRIVE AND
REAR BRAKE ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792T-422-1610 Spacer ■ 4 N
J 1 01011-61620 Bolt ■ 4
01643-31645 Washer ■ 4
REMOVAL
6. Remove retainer (7) and shim (8).
1. Remove the dump body assembly. For details, ★ Before removing the retainer completely,
see REMOVAL, INSTALLATION OF DUMP pass a guide bolt through the retainer, and
BODY ASSEMBLY". then pull out the retainer and ring gear
assembly together slowly and sling them.
2. Remove the (outer and inner) rear wheel assem- ★ Check the thickness and quantity of the
blies on the side of the final drive and rear brake shims.
assembly to be removed. For details, see
REMOVAL, INSTALLATION OF REAR WHEEL
ASSEMBLY.
3. Remove the final drive carrier assembly. For

FINAL DRIVE CARRIER ASSEMBLY.
4. Release the parking brake. For details, see

TESTING AND ADJUSTING, emergency method
of releasing parking brake.
5. Using tool J1, fix outer gear (5) and wheel hub
(6).
★ Be sure to install tool J1 to protect the float-
ing seal before removing the retainer. 7. Remove ring gear assembly (9).
Ring gear assembly: 100 kg
HD465-7, HD605-7 30-93

➂
8. When disassembling the ring gear assembly, ★ Since bearing (16) comes off, take care not
remove bolt (10) and take the assembly apart to drop it.
into holder (11), inner hub (12), and ring gear
(13).
★ For disassembly and assembly, see DISAS-

S E M B LY A N D A S S E M B LY O F F I N A L
9. Sling final drive and rear brake assembly (14) DRIVE, REAR BRAKE, AND PARKING
temporarily. BRAKE ASSEMBLY.
10. Remove 31 bolts (15) and pull out final drive and
rear brake assembly (14) sideway to remove it.
Final drive and rear brake assembly:
800 kg
30-94 HD465-7, HD605-7

➂
INSTALLATION
removal.
After installing, be sure to remove tool J1 and

parking brake releasing bolt.
• Adjusting preload on bearing

1) Install retainer (7) without inserting any shim
and tighten 3 mounting bolts to the following
torque.
★ Rotating the hub 20 – 30 turns, tighten
the bolts evenly to the specified torque.
181 – 191 Nm {18.5 – 19.4 kgm}
[Target: 186 Nm {18.9 kgm}
2) Measure distance a between the end of tube
(17) and end of retainer (7) with depth
micrometer [2].
★ Measure at 2 places and obtain the aver-
age.
3) Remove retainer (7) and measure its thick-
ness b.
★ Measure at 2 places and obtain the aver-
age.
4) Calculate shim thickness c by the following
expression.
c (mm) = a – b + 0.3
5) Install the shim of the calculated thickness
and retainer (7) with the all mounting bolts (6
bolts).
★ Rotating the hub 20 – 30 turns, tighten
the bolts evenly to the specified torque.
Mounting bolt:
785 – 980 Nm {80.1 – 99.9 kg}
6) Rotate the wheel hub again and check that it
revolves normally.
HD465-7, HD605-7 30-95

➂
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOL
SKETCH OF SPECIAL TOOL

Spacer J1
30-96 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE

TION OF FINAL DRIVE, REAR
BRAKE, AND PARKING
BRAKE ASSEMBLY
REMOVAL
1. Perform Steps 1 - 7 of REMOVAL, INSTALLA-
TION OF FINAL DRIVE AND REAR BRAKE
ASSEMBLY.
★ If the final drive, rear brake, and parking
brake assembly does not need to be disas-
sembled after removed, the parking brake
does not need to be released.
★ Since bearing (16) comes off, take care not
2. Disconnect hoses (1) and (2) and remove pipes to drop it.
(3) and (4).
3. Sling final drive, rear brake, and parking brake

assembly (5) temporarily. INSTALLATION
4. Remove 30 nuts (6) and pull out final drive, rear • Carry out installation in the reverse order to
brake, and parking brake assembly (5) sideway removal.
to remove it.
Final drive, rear brake, and parking
brake assembly: 1,100 kg Mounting nut of final drive, rear brake,
and parking brake assembly:
455 – 565 Nm {46.4 – 57.6 kgm}
• Adjusting preload on bearing

See REMOVAL, INSTALLATION OF FINAL
DRIVE AND REAR BRAKE ASSEMBLY.
HD465-7, HD605-7 30-97

➂
DISASSEMBLY AND ASSEM- 3. Parking brake assembly

1) Check that the parking brake is released.
BLY OF FINAL DRIVE, REAR (See TESTING AND ADJUSTING, Emer-
BRAKE, AND PARKING gency method of releasing parking brake.)
BRAKE ASSEMBLY 2) Remove parking brake assembly (1).
★ Make match marks on parking brake
assembly (1) and outer gear (5) for refer-
Special tools
ence for installation.
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792T-422-1610 Spacer ■ 4 N
1 01011-61620 Bolt ■ 4
01643-31645 Washer ■ 4
2 795-102-2102 Spring washer ■ 1
J
792-520-2110 Installer ■ 1
3
792-530-1600 Push tool ■ 1
791-585-1510 Installer ■ 1
4
791-530-1700 Push tool ■ 1
• For the sketch of tool J1, see REMOVAL,

4. Disassembly of parking brake assembly
INSTALLATION OF FINAL DRIVE AND REAR
BRAKE ASSEMBLY. Since the installing load on the internal
spring is large, disassemble the assembly
DISASSEMBLY carefully according to the following proce-
dure.
Remove the internal parts (piston, damper, 1) Gradually loosen and remove parking brake
disc, plate, floating seal, etc.) carefully so that releasing bolts A (10 pieces).
they will not be damaged by impacts, fall, etc. ★ Loosen all releasing bolts A evenly so
that the internal brake piston will not
1. Place the final drive, rear brake, and parking slant.
brake assembly with the parking brake side up. Reference: Total installing load on spring:
Using blocks, etc., place the assembly sta- Approx. 199 kN {20.3 ton}
bly.
2. Remove tool J1 which is fixing outer gear (5) and

wheel hub (6).
30-98 HD465-7, HD605-7

➂
2) Turn over the parking brake assembly. 6) Remove seal rings (8) and (9) from cylinder
3) Gradually loosen and remove 13 cylinder (7).
mounting bolts (4).
7) Remove 30 springs (10) from cylinder (2).

4) Remove cylinder (7). ★ There are 22 double springs and 8 single
★ Make match marks on cylinder (7) and springs.
piston assembly (3) for reference for ★ Make distinction marks at locations of the
installation. single springs (8 places) with paint for
reference for installation.
5) Remove piston assembly (3).

★ Make match marks on piston assembly 8) Turn over the piston assembly disassembled
(3) and cylinder (2) for reference for in Step 5).
installation. 9) Using tool J2, compress the springs and
remove pin (11), washer (12), spring (13),
and guide (14).
HD465-7, HD605-7 30-99

➂
5. Dampers, discs, plates, and spacer

1) Remove plates (19).
10) Remove parking brake piston (15).

★ Make match marks on parking brake pis- 2) Remove damper (20), 12 discs (21), 11
ton (15) and brake piston (16) for refer- plates (22), and damper (23).
ence for installation.
11) Remove seal rings (17) and (18) from brake

piston (16).
30-100 HD465-7, HD605-7

➂
3) Install bolts [3] to the sling taps and remove 7. Inner gear
spacer (24). 1) Remove inner gear (27).
6. Outer gear 2) Remove floating seal (28) on the outside of

1) Remove outer gear (5). the inner gear, retainer (29), and floating seal
★ Take care not to drop the floating seal (30) on the inside of the inner gear.
from the bottom.

2) Remove oil seal (25) and floating seal (26) 1) Remove retainer and floating seal assembly
from outer gear (5). (31).
★ Retainer and floating seal assembly (31)
is free when the inner gear (in the previ-
ous section) is removed.
HD465-7, HD605-7 30-101

➂
2) Remove floating seal (33) from retainer (32).
3) Remove bearing (34).
4) Remove outer races (35) and (36).
30-102 HD465-7, HD605-7

➂
ASSEMBLY
★ Clean the all parts and check them for dirt or
damage.
★ Coat the sliding surfaces with engine oil before
installing.
★ Remove the white powder from the O-ring sur-
face of the floating seal with engine oil, etc.
Even a slight flaw of the floating seal made by

an impact, fall, etc. can cause oil leakage.
Accordingly, install the floating seal carefully.

1) Install outer races (35) and (36).
4) Set retainer and floating seal assembly (31)
to the center.
★ Set the assembly with the floating seal
side up.
2. Inner gear
1) Using tool J3, install floating seal (30) to the
inside of inner gear (27).
3) Using tool J3, install floating seal (33) to

retainer (32).
★ Thinly apply grease (G2-LI) to the top of
the floating seal.
2) Install retainer (29) to inner gear (27).

3) Using tool J4, install floating seal (28).
★ Thinly apply grease (G2-LI) to the top of
the floating seal.
HD465-7, HD605-7 30-103

➂
3. Outer gear
1) Using tool J4, install floating seal (26).
★ After installing, measure distance a

between the end of retainer (29) and end ★ After installing, measure distance b
of seal (28) at 4 points on the periphery. between the end of outer gear (5) and
Check that the difference between the end of seal (26) at 4 points on the periph-
values at the 4 points does not exceed 1 ery. Check that the difference between
mm. the values at the 4 points does not
exceed 1 mm.
4) Install inner gear (27).

★ When installing the inner gear, match it to 2) Install oil seal (25).
the retainer and floating seal assembly ★ Apply grease to part P shown below.
installed in Step 1-4). Part P: Grease (G2-LI)
★ Take care not to damage the floating
seal.
Inner gear mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
30-104 HD465-7, HD605-7

➂
3) Install outer gear (5).

★ Take care not to drop the floating seal
from the bottom.
★ Take care that the oil seal at the bottom
will not be rolled up.
3) Install discs (21) and plates (22) alternately

in order.
★ Install the 12 discs and 11 plates.
4) Install damper (20).
4. Dampers, discs, plates, and spacer
1) Install bolts [3] to the sling taps, and then
install spacer (24).
★ Install damper (20) with seat b (projected

part: 4.5 mm thick) up.
If the damper is installed reversely, the
★ Install spacer (24) with the chamfered
disc will be worn abnormally. Accord-
side down.
ingly, be sure to install it in the correct
2) Install damper (23).
direction.
★ Install damper (23) with seat a (projected
part: 1 mm thick) down.
If the damper is installed reversely, the
disc will be worn abnormally. Accord-
ingly, be sure to install it in the correct
direction.
HD465-7, HD605-7 30-105

➂
5) Install plates (19). 3) Pass guide (14) through spring (13) and install
them to the parking brake piston.
4) Using tool J2, compress spring (13) and install
washer (12) from the underside of the brake
piston. Pass pin (11) through guide (14) to
fix the guide.
5. Assembly of parking brake assembly

Since the installing load on the internal
spring is large, assemble the assembly
carefully according to the following proce-
dure.
1) Install seal rings (17) and (18) to brake piston
(16).
Grease (G2-LI)
2) Install parking brake piston (15) to brake pis-

ton (16).
★ Match the match marks made when the
piston was removed.
30-106 HD465-7, HD605-7

➂
5) Install 30 springs (10) to cylinder (2). ★ When installing the piston assembly,
★ For the locations of the 8 single springs, match it to dowel pin C.
see the distinction marks made when
they were removed.
8) Install guide bolt [2] and cylinder (7).

6) Install seal rings (8) and (9) to cylinder (7). cylinder was removed.
Periphery of seal ring: ★ Match the faucet joint portion of cylinder
Grease (G2-LI) (7) to that of cylinder (2) by hitting cylin-
der (7) evenly with a plastic hammer, etc.
7) Install piston assembly (3) to cylinder (2).

★ Match the match marks made when the 9) Tighten 13 cylinder mounting bolts (4) gradu-
piston assembly was removed. ally and evenly to the specified torque.
Mounting bolt:
153 – 190 Nm {15.6 – 19.3 kgm}
HD465-7, HD605-7 30-107

➂
10) Apply hydraulic pressure to parking brake 7. Using tool J1, fix outer gear (5) and wheel hub
releasing port P (20 x 1.5) and check that the (6).
piston is pulled up and the parking brake
works.
• Parking brake releasing pressure:
8.7 MPa {85 kg/cm2}
★ Fix outer gear (5) and wheel hub (6) at fol-

lowing points a, b, c, and d (4 places in
total).
11) Tighten parking brake releasing bolts A (10

pieces) gradually and evenly.
6. Install parking brake assembly (1) to outer gear

(5).
parking brake assembly was removed.
30-108 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER

TION OF FRONT SUSPENSION
CYLINDER ASSEMBLY
REMOVAL
1. Remove the front wheel assembly. For details,
see REMOVAL, INSTALLATION OF FRONT
WHEEL ASSEMBLY.
2. Remove the front brake calipers assembly. For

FRONT BRAKE CALIPERS ASSEMBLY.
3. Remove the wheel hub assembly. For details,

see REMOVAL, INSTALLATION OF FRONT 9. Remove 4 bolts (8).
WHEEL HUB ASSEMBLY. 1) Revolve the knuckle arm toward the truck
body about 40 degrees and remove the bolt
4. Release nitrogen gas. For details, see TESTING marked with ●.
AND ADJUSTING, Testing and adjusting front 2) Return the knuckle arm to its original position
suspension cylinder. and jack up the king pin and remove the
bolts marked with .
10. Using a forklift, etc., sling the front suspension

6. Disconnect tubes (2) and (3). cylinder assembly and pull out pin (9) on the rod
side.
7. Pull out pin (4) and disconnect tie rod (5).
11. Disconnect and remove front suspension cylin-
8. Pull out pin (6) and remove steering cylinder (7). der assembly (10) from the knuckle arm.
Front suspension cylinder assembly:
500 kg
HD465-7, HD605-7 30-109

➂
INSTALLATION
removal.
[*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
k Before operating the steering system after

them.
finishing installation, be sure to refill the

front suspension cylinder with nitrogen gas
and adjust it. For details, see TESTING
AND ADJUSTING, Testing and adjusting
front suspension cylinder.
30-110 HD465-7, HD605-7

(8)
DISASSEMBLY AND ASSEM- 2. Remove air intake valve (1) and oil level valve
(2).
BLY OF FRONT SUSPENSION
CYLINDER ASSEMBLY 3. Removal of cylinder rod assembly.
(Standard cylinder) 1) Remove flange mounting bolts (3) and air
bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
Special tools
retainer (7), and flange (8) together.
New/Remodel
Symbol
Necessity
Part No. Part name
4. Disassembly of flange
Sketch
1) Remove plate (6), retainer (7), and flange (8)
Q'ty
from rod assembly (5).
792-103-4102 Push tool t 1 2) Remove dust seal (9) and bushing (10) from
1 790-101-5421 Grip t 1 retainer (7).
3) Remove U-packing (11) and bushing (12)
01010-81240 Bolt t 1
Q from flange (8).
2 792-610-1100 • Pump assembly 1 5. Remove wear ring (13) from cylinder rod (5).
792-610-1200 • Charging tool 1
DISASSEMBLY
• Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
HD465-7, HD605-7 30-111

(8)
ASSEMBLY 2) Press fit bushing (10) to retainer (7) and

(See the figure for disassembly, too.) install dust seal (9).
★ When press fitting the bushing, take care
1. Installation of wear ring not to deform it.
Install wear ring (13) to cylinder rod (5). Periphery of seal:
Outside of wear ring: Adhesive (LT-2)
3. Assembly of cylinder rod assembly
2. Assembly of flange 1) Install flange (8), retainer (7), and plate (6) to
1) Using tool Q1, press fit bushing (12) to flange the cylinder rod.
(8) and install U-packing (11). Mating faces of flange and retainer:
Inside of bushing: Gasket sealant (LG-6)
★ When installing the U-packing, check ★ Apply the gasket sealant evenly to
that there are 4 projections on the top of hatched part B and apply it thinly to U-
the inside lip. packing C so that it will not be projected.
★ Apply rust-preventive oil to part A indi- 2) Using a block, erect the cylinder.
cated with 2-dot chain lines on the ★ Fill the cylinder with engine oil.
periphery of the U-packing (NISSEKI
Cylinder: Approx.
P1300 or equivalent).
16.5 (EO10-CD)
3) Sling cylinder rod assembly (5) and install it

to the cylinder.
★ If the rod assembly is inserted too deep,
the oil spouts out. Stop it to a position
where the oil does not spout out.
★ After installing the front suspension assem-
bly to the truck body, adjust the oil and
gas, using tool Q2. For details, see
TESTING AND ADJUSTING FRONT
SUSPENSION CYLINDER.
4) Install flange (8), retainer (7), and plate (6) to

the cylinder with bolts (3).
Mounting bolt:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
30-112 HD465-7, HD605-7

➂
5) Install air bleeding valve (4).

Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install oil level valve (2) and air intake valve (1).
Oil level valve and air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
★ The dust cover consists of 2 pieces. Reduce
the clearance between them to 0.5 mm or
less.
HD465-7, HD605-7 30-113

➂
DISASSEMBLY AND ASSEM- 2. Remove air intake valve (1) and oil level valve
(2).
BLY OF FRONT SUSPENSION
CYLINDER ASSEMBLY 3. Removal of cylinder rod assembly.
(Cylinder with buffer ring) 1) Remove flange mounting bolts (3) and air
bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
Special tools
retainer (7), and flange (8) together.
New/Remodel
Symbol
Necessity
Part No. Part name
4. Disassembly of flange
Sketch
1) Remove plate (6), retainer (7), and flange (8)
Q'ty
from rod assembly (5).
792-103-4102 Push tool t 1 2) Remove dust seal (9) and bushing (10) from
1 790-101-5421 Grip t 1
retainer (7).
3) Remove U-packing (11), buffer ring (14) and
01010-81240 Bolt t 1
bushing (12) from flange (8).
Q
2 792-610-1100 • Pump assembly 1 5. Remove wear ring (13) from cylinder rod (5).
792-610-1200 • Charging tool 1
DISASSEMBLY
• Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
30-113-1 HD465-7, HD605-7

(8)
ASSEMBLY k Buffer ring (14) is made of 2 parts. When

(See the figure for disassembly, too.) installing it, set the round corner of part [2]
(Black) inside of part [1] (Blue).
1. Installation of wear ring • The side indicated by the arrow is the pres-
2 Outside of wear ring:

Install wear ring (13) to cylinder rod (5). sure side.
2. Assembly of flange
1) Using tool Q1, press fit bushing (12) to flange
(8) and install U-packing (11) and buffer ring
2 Inside of bushing:
(14).

a When installing the U-packing, check
that there are 4 projections on the top of
the inside lip.
2) Press fit bushing (10) to retainer (7) and

install dust seal (9).
a When press fitting the bushing, take care
2 Periphery of seal:
not to deform it.
Adhesive (LT-2)
3. Assembly of cylinder rod assembly

2 Mating faces of flange and retainer:

the cylinder rod.

a Apply rust-preventive oil to part A indi-
cated with 2-dot chain lines on the a Apply the gasket sealant evenly to
periphery of the U-packing (NISSEKI hatched part B and apply it thinly to U-
P1300 or equivalent). packing C so that it will not be projected.
2) Using a block, erect the cylinder.

a Fill the cylinder with engine oil.
5 Cylinder: Approx.
16.5 l (EO10-CD)
HD465-7, HD605-7 30-113-2

(8)

to the cylinder.
a If the rod assembly is inserted too deep,
the oil spouts out. Stop it to a position
where the oil does not spout out.
a After installing the front suspension assem-
bly to the truck body, adjust the oil and
gas, using tool Q2. For details, see
TESTING AND ADJUSTING FRONT
SUSPENSION CYLINDER.
3 Mounting bolt:
the cylinder with bolts (3).
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}

5) Install air bleeding valve (4).
3 Oil level valve and air intake valve:

4. Install oil level valve (2) and air intake valve (1).
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
a The dust cover consists of 2 pieces. Reduce
the clearance between them to 0.5 mm or
less.
30-113-3 HD465-7, HD605-7

(8)
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER

TION OF REAR SUSPENSION • Carry out installation in the reverse order to
removal.
CYLINDER ASSEMBLY
REMOVAL ,
Stop the truck on level ground and set the park- When aligning the pin holes, never insert
ing brake switch to the PARK position, then lock your fingers in them.
# Refill the rear suspension cylinder with nitro-
Disconnect the cable from the negative (–) ter- gen gas and adjust it. For details, see TEST-
minal of the battery. ING AND ADJUSTING, Testing and adjusting
rear suspension cylinder.
1. Release nitrogen gas. For details, see TESTING
AND ADJUSTING, Testing and adjusting rear
suspension cylinder.
2. Remove protector (1).
3. Using a forklift, etc., sling the rear suspension

cylinder assembly and pull out pin (2) on the bot-
tom side.
4. Pull out pin (3) on the rod side and remove rear
suspension cylinder assembly (4).
Rear suspension cylinder assembly:
180 kg
30-114 HD465-7, HD605-7

"

BLY OF REAR SUSPENSION
CYLINDER ASSEMBLY
(Standard cylinder)
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-625-1300 Push tool t 1
1 790-101-5421 Grip t 1
01010-81240 Bolt t 1
Q 5. Flange and retainer
1) Remove retainer (6) and flange (8) from cyl-
2 792-610-1100 • Pump assembly 1
inder rod assembly (7).
792-610-1200 • Charging tool 1 2) Remove U-packing (10), backup ring, and O-
ring (11) from flange (8).
DISASSEMBLY 3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
1. Guard retainer (6).
Sling the cylinder assembly and loosen clamp
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.
3. Air intake valve and oil level valve

Remove cover (3), air intake valve (4), and oil
level valve (5).
6. Wear ring
Remove wear ring (15) from rod (16).
4. Cylinder rod assembly

1) Erect the cylinder assembly upside down.
2) Remove the mounting bolt of retainer (6).
3) Slowly sling and remove cylinder rod assem-
bly (7), retainer (6), and flange (8) as 1 unit
from cylinder (9) with a crane.
HD465-7, HD605-7 30-115

(8)
ASSEMBLY 3. Retainer
1) Using tool Q1, install bushing (14) to retainer
1. Wear ring (6).
Install wear ring (15) to rod (16). 2) Install seal (13) to retainer (6).
Periphery of seal: Adhesive (LT-2)
2. Flange
1) Using tool Q1, install bushing (12) to flange
(8).
1) Using a block, erect cylinder (9).
2) Install U-packing (10) to flange (8).
★ Apply rust-preventive oil to part A indi-
to cylinder (9).
cated with 2-dot chain lines on the
3) Install flange (8) and retainer (6) to cylinder
rod assembly (7).
3) Install backup ring and O-ring (11) to flange Mating faces of flange and retainer:
(8). Gasket sealant (LG-6)
★ Apply the gasket sealant evenly to
hatched part B and apply it thinly to U-
packing C so that it will not be projected.
30-116 HD465-7, HD605-7

➂
4) Install retainer (6) and flange (8) together to 6. Guard

cylinder (9) with the mounting bolts. 1) Install guard (2) and secure it with clamp (1).
Mounting bolt: Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}
98 – 123 Nm {10.0 – 12.5 kgm}

1) Set the cylinder assembly upside down.
2) Sling the cylinder so that dimension D on its
bottom side will be 140 ± 3 mm.
3) Supply oil through the oil level port with the

oil level pump and spout oil from the air
intake port until bubbles do not come out any
more.
4) After supplying oil, install oil level (5) and air
intake valve (4).
Air intake valve and oil level:
39.2 – 49.0 Nm {4 – 5 kgm}
5) Install cover (3).
HD465-7, HD605-7 30-117

➂

BLY OF REAR SUSPENSION
CYLINDER ASSEMBLY
(Cylinder with buffer ring)
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-625-1300 Push tool t 1
1 790-101-5421 Grip t 1
01010-81240 Bolt t 1
Q 5. Flange and retainer
1) Remove retainer (6) and flange (8) from cyl-
2 792-610-1100 • Pump assembly 1
inder rod assembly (7).
792-610-1200 • Charging tool 1 2) Remove U-packing (10), buffer ring (17),
backup ring and O-ring (11) from flange (8).
DISASSEMBLY 3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
1. Guard retainer (6).
Sling the cylinder assembly and loosen clamp
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.

Remove cover (3), air intake valve (4), and oil
level valve (5).
6. Wear ring
Remove wear ring (15) from rod (16).

1) Erect the cylinder assembly upside down.
2) Remove the mounting bolt of retainer (6).
3) Slowly sling and remove cylinder rod assem-
bly (7), retainer (6), and flange (8) as 1 unit
from cylinder (9) with a crane.
30-117-1 HD465-7, HD605-7

(8)
ASSEMBLY
1. Wear ring
Install wear ring (15) to rod (16).
3. Retainer
1) Using tool Q1, install bushing (14) to retainer
(6).
2. Flange
2 Periphery of seal: Adhesive (LT-2)
2) Install seal (13) to retainer (6).
1) Using tool Q1, install bushing (12) to flange
(8).
2) Install U-packing (10) and buffer ring (17) to
flange (8).
a Apply rust-preventive oil to part A indi-
cated with 2-dot chain lines on the
k Buffer ring (17) is made of 2 parts. When

installing it, set the round corner of part [2]

(Black) inside of part [1] (Blue).
3) Install backup ring and O-ring (11) to flange
(8).

1) Using a block, erect cylinder (9).
to cylinder (9).
3) Install flange (8) and retainer (6) to cylinder
2 Mating faces of flange and retainer:

rod assembly (7).
HD465-7, HD605-7 30-117-2

(8)
a Apply the gasket sealant evenly to 5. Air intake valve and oil level valve
hatched part B and apply it thinly to U- 1) Set the cylinder assembly upside down.
packing C so that it will not be projected. (Set the rod down.)
2) Sling the cylinder so that dimension D on the
rod side will be as follows.
When buffer ring is not installed: 140 ± 3 mm
When buffer ring is installed: 124 ± 3 mm
3) Supply oil through the oil level port with the

oil level pump and spout oil from the air
intake port until bubbles do not come out any
more.
4) After supplying oil, install oil level (5) and air
3 Air intake valve and oil level:

intake valve (4).
39.2 – 49.0 Nm {4 – 5 kgm}

5) Install cover (3).
4) Install retainer (6) and flange (8) together to
3 Mounting bolt:
cylinder (9) with the mounting bolts.
98 – 123 Nm {10.0 – 12.5 kgm}
6. Guard
3 Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}

1) Install guard (2) and secure it with clamp (1).
30-117-3 HD465-7, HD605-7

(8)
DISASSEMBLY AND ASSEMBLY RETARDER COOLING PUMP

TION OF RETARDER COOL-
ING PUMP ASSEMBLY
REMOVAL
pin.
1. Disconnect tubes (1) and (2) and hose (3).

# Prepare a pan to receive oil from the joints.
2. Remove retarder cooling pump assembly (4).

Retarder cooling pump assembly: 30 kg
INSTALLATION
removal.

30-118 HD465-7, HD605-7

"
DISASSEMBLY AND ASSEMBLY STEERING, HOIST, AND HOIST CONTROL PUMP

TION OF STEERING, HOIST, • Carry out installation in the reverse order to
AND HOIST CONTROL PUMP removal.
ASSEMBLY • Refilling with oil
REMOVAL Run the engine to circulate the oil through the
Stop the truck on level ground and set the park- system. Then, check the oil level again.
ing brake switch to the PARK position, then lock Transmission case: 190 (EO30-CD)
pin.
1. Disconnect tubes (1) and (2) and hoses (3), (4),

and (5).
★ Prepare a pan to receive oil from the joints.
2. Remove steering, hoist and hoist control pump

assembly (6).
Steering, hoist and hoist control pump
assembly: 35 kg
HD465-7, HD605-7 30-119

➂
TORQUE CONVERTER, TRANSMISSION AND
DISASSEMBLY AND ASSEMBLY RETARDER COOLING, AND BRAKE PUMP

TION OF TORQUE CON-
VERTER, TRANSMISSION
AND RETARDER COOLING,
AND BRAKE PUMP ASSEM-
BLY
REMOVAL
pin.
1. Disconnect tubes (1), (2), and (3) and block (4).

★ Prepare a pan to receive oil from the joints.
2. Remove torque converter, transmission and

retarder cooling, and brake pump assembly (5).
Torque converter, transmission and retarder
cooling, and brake pump assembly: 25 kg
INSTALLATION
removal.

30-120 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY STEERING VALVE

TION OF STEERING VALVE • Carry out installation in the reverse order to
ASSEMBLY removal.
REMOVAL
★ Since the yoke fixing bolt has fine threads,
Stop the truck on level ground and set the park- do not apply excessive force to it to damage
ing brake switch to the PARK position, then lock the threads.
loosen the hydraulic oil filler cap slowly to
release the internal pressure of the hydraulic
tank.
1. Remove yoke fixing bolt (1).

★ Fix yoke (2) to the upper part with ropes, etc.
so that it will not come off the spline of the
column shaft.
2. Remove cover (3).
3. Disconnect hoses (4), (5), (6), (7), and (8).
4. Remove steering valve assembly (9).

★ Using ropes, etc., lift off the steering valve
assembly.
HD465-7, HD605-7 30-121

➂
DISASSEMBLY AMD ASSEM- DISASSEMBLY

BLY OF STEERING VALVE 1. Remove 7 mounting bolts (1). Insert a screw-
ASSEMBLY driver between end cover assembly (2) and case
(3) to remove end cover assembly (2).
★ Securing of clean working condition ★ After removing the end cover assembly,
check the edges of the end cover hole for
1. Cleanliness is essential to maintenance of the breakage.
power steering system. The hydraulic circuit
must be isolated from impurities.
2. When disassembling any part of the unit, pre-

pare a clean worktable.
3. Before disconnecting a pipe, wipe off the exter-

nal dirt from it.
4. Before placing the unit on the worktable, be sure

to wipe off the external dirt from it.
5. After disassembling the unit, clean the parts in

kerosene-based solvent free of impurities and
dry them by blowing dry compressed air free of 2. Remove commutator (5) and washer (6).
impurities against them. ★ Do not remove pin (4).
★ If any solvent other than the above is used, it
can deteriorate the rubber seals. Never wipe
the parts with cloths or blow steam against
the unit.
★ Since the solvent is combustible material,
handle it carefully and keep it off fire.
PREPARATION
1. Stop up the 5 ports of the valve body with plugs

and clean the outside of the valve, and then
remove the plugs.
2. Install tube nut [1] to one of the ports.
3. Install the valve body to vise [2] with the end

cover up.
★ Do not hold the valve body directly with the
vise. If it is held so, the unit may be broken.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name

Sketch
Q'ty
1 790-452-1200 Pilot ring tool ■ 1

T
2 790-452-1100 Tool installer set ■ 1
30-122 HD465-7, HD605-7

➂
3. Using 2 mounting bolts (1), remove commutator 9. Install valve body (11) to the vise with input shaft
ring (7) and manifold (8). (18) up and make match marks A on upper case
(19) and valve body (11).
4. Using 2 mounting bolts (1), remove rotor assem-
bly (9) and wear plate (10) similarly to the com- 10. Remove 4 mounting bolts (20) and raise input
mutator ring and manifold. shaft (18) to remove input shaft, upper case, and
valve spool assembly (23).
★ The valve spool is fitted to the body with very
narrow clearance between them. Accord-
ingly, if it is pressed sideway, it cannot be
pulled out completely. When removing it
from the housing, never apply an excessive
force to it.
5. Insert a screwdriver between case (3) and valve

body (11) to remove case (3).
6. Remove drive link (12).
7. Remove ball (13).
8. Remove rod (14), roller (15), rod (16), and spring

(17).
HD465-7, HD605-7 30-123

➂
11. Remove upper case assembly (22) from input 14. Using pin [3] (ø 3.0 mm, = Min. 16 mm),
shaft and valve spool assembly (23), and then remove needle roller (36) from input shaft (18).
remove shim (24) and spacer (25). ★ Perform this work on a wood block so that
★ Check the thickness and quantity of the the input shaft will not be damaged.
shims.
15. Direct valve spool (37) down and remove torsion

12. Remove seal (26) and snap ring (27), and then bar (38) and spacer (39) from the input shaft and
remove spacer (28), ring (29A), seal (29), and valve spool assembly.
seal ring (30) from upper case (19). ★ Do not remove needle roller (40) from the
★ Usually, seal (29) and seal ring (30) are in 1 torsion bar.
unit.
13. Remove snap ring (31), thrust washer (32),

thrust bearing (33), thrust washer (34), and wave
washer (35) from input shaft (18).
30-124 HD465-7, HD605-7

➂
16. Direct valve spool (37) down and revolve input ASSEMBLY
shaft (18) until drive link (41) comes off.
★ Before assembling, clean the parts in based-
17. Direct valve spool (37) down and rotate input based solvent free of impurities and dry them by
shaft (18) clockwise until ball (42) comes off. blowing dry compressed against them. Never
★ Since ball (42) may come off by itself, take wipe them with cloths.
care not to lose it. ★ Check the edges of the lapped surface for paint.
★ Do not apply oil to the parts to be installed,
★ Replace the all seals with new ones.
1. Set thrust washer (34), thrust bearing (35), and

thrust washer (32) in order to input shaft (18),
and then install snap ring (31).
★ Thrust washer (32) is larger than thrust
washer (34).
★ Remove ball retaining spring (43) only when

replacing it. When removing it, hold its flat
end with priers and raise it until it is removed
from valve spool (37). Take care not to dam-
age the periphery of the valve spool and con-
trol edge.
2. Install wave washer (35) to thrust bearing (33)

and thrust washer (34).
3. Install ball (42) to inside of valve spool (37).
HD465-7, HD605-7 30-125

➂
4. Insert input shaft (18) in valve spool (37), rotating 6. Check the splines of drive link (41) and input
it counterclockwise so that the ball will be fitted to shaft (18), and then install drive link (41), match-
its groove. ing the spline of valve spool (37).
★ Keep the spool horizontally during this work.
★ If the splines of the drive link and input shaft

5. Set the intermediate part of torsion bar (38) are not meshed with each other, rotate the
between thrust washer (34) and valve spool (37). input shaft a little to mesh them, and then
★ If the torsion bar is set as above, the valve insert the drive link.
spool and input shaft is positioned. ★ Set the torsion bar securely.
★ Rotate the input shaft in the spool projecting
direction (clockwise) until it stops. If the drive
link is installed correctly, a clearance of 8 – 9
mm is made between the thrust washer and
valve spool.
30-126 HD465-7, HD605-7

➂
7. Measure diameter of needle roller (40) of tor- 11. Install spacer (25) to the input shaft and valve
sion bar (38) at several points. Check that the spool.
difference between measured diameters does ★ When installing the spacer, direct lip surface
not exceed 0.025 mm. "B" in it toward washer (35).
8. Set spacer (39) to torsion bar (38) and insert 12. Install input shaft and valve spool assembly (23)
them in valve spool and input shaft assembly to valve body (11).
(23). ★ The valve spool is fitted to the body with very
narrow clearance between them. Accord-
ingly, if it is pressed sideway when installed,
it may not operate normally.
13. Set shim (24) on thrust washer (32). Apply

grease to new seal (19B) and fix it to the groove
of upper case (19). Install upper case (19),
matching match marks A, and tighten mounting
bolts (20) lightly.
9. Using pin [3] (Outside diameter: 3 mm), align the

pin holes of torsion bar (38) and input shaft (18).
10. Using pin [3], drive needle roller (36) in input

shaft to a depth of 0.8 mm.
★ Check that needle roller (36) is not projected
from the inspection sheet.
HD465-7, HD605-7 30-127

➂
14. Set tool T1 so that the valve body will be aligned 17. Pull down and fix input shaft (18) and mesh drive
with the upper case. link (12) with the spline of the valve spool, and
then rotate the spool so that its end will be flush
with the valve body.
18. Remove drive link (12) again and adjust its posi-
tion so that needle roller (40) of the torsion bar
will be in its groove. Then, insert drive link (12)
in spool (37).
15. Tighten 4 upper case mounting bolts and remove

tool T1.
Mounting bolt:
24.40 – 29.80 Nm {2.49 – 3.04 kgm}
★ Install the valve body to a vise with the input
shaft down.
16. Measure groove width of drive link (12) at sev- 19. Using depth gauge [4], measure fitting height h
eral points over the length and check that the dif- of the valve spool above the valve body.
ference between the obtained values does not
exceed 0.025 mm.
★ If fitting height h is below 0.063 mm, do not

adjust the shim.
If fitting height h is larger than 0.063 mm,
adjust the shim by repeating Steps 12 – 19
so that h will be below 0.063 mm.
30-128 HD465-7, HD605-7

➂
20. Install ball (13). 23. Lubricate a new seal and the seal groove with
grease and install ring (11A) and seal (11B) to
21. Set rod (16) to spring (17) and install them to valve body (11) in order.
valve body (11). Then, install roller (15) and rod
(14).
24. Using guide pin [6], install wear plate (10), rotor
assembly (9), manifold (8), and commutator ring
22. Before installing the rotor, check it according to (7).
the following procedure.
1) Set end cover assembly (2) with the pin side
up and set rotor assembly (9) with the rotor
spline side down, and then check that the
rotor rotates freely in the stator.
2) Measure thickness of rotor A and that of sta-

tor B at several points and check that the
each difference between them is below 0.18
mm.
3) Using filler gauge [5], the clearance between
stator B and rotor A is below 0.18 mm.
HD465-7, HD605-7 30-129

➂
25. Lubricate the inside of both ends of case (3) and ★ Set the oval hole of the commutator and one
the seal installed to valve body (11) with grease. of the bolt holes of the end cover assembly in
line.
26. Install case (3) to valve body (11).
★ Install end cover (2) to the end of the case
and tighten the mounting bolts (1) evenly so
that the case will be inserted straight.
27. Remove end cover (2) and lubricate a new seal

and the seal groove with grease, and then install
ring (2A) and seal (2B) to the end cover in order.
29. Rotate the input shaft so that the end of drive link
(12) will be inserted in the oval hole of the com-
mutator.
★ Lubricate the seal in the end cover with
grease.
30. Set end cover assembly (2) on cover (3) and

tighten the 5 mounting bolts evenly.
28. Apply grease to end cover assembly (2) and fit Mounting bolt:
washer (6) and commutator (5) so that they will 61.0 – 74.5 Nm {6.22 – 7.66 kgm}
not fall even if they are set down. ★ Tighten the mounting bolts in the diagonal
★ Install the commutator so that its hollow C order so that the sleeve and end cover will
will be on the end cover assembly side. not slant while they are being installed.
31. Remove guide pin [6] and tighten the remaining

2 bolts evenly.
Mounting bolt:
61.0 – 74.5 Nm {6.22 – 7.66 kgm}
30-130 HD465-7, HD605-7

➂
32. Direct the input side up and wind tapes onto the 33. Apply grease to the inside and outside of seal
serrated part. (29) and seal ring 30 and install them with the lip
★ Seal (26), spacer (28), ring (29A), seal (29), side in the valve.
and seal ring (30) are the parts of a kit.
★ Seal (29) and seal ring (30) have been 34. Install ring (29A).
installed as 1 unit.
35. Using tool T2, install spacer (28) from the small
diameter end.
36. Install snap ring (27) with its rounded side in the
valve.
37. Install seal (26) to the upper case.

★ When installing seal (26), apply grease to its
inside and outside.
HD465-7, HD605-7 30-131

➂
DISASSEMBLY AND ASSEMBLY DEMAND VALVE

TION OF DEMAND VALVE
ASSEMBLY
REMOVAL
pin.
1. Drain hydraulic oil.

Hydraulic tank: 122
2. Disconnect tubes (1), (2), (3), and (4).
3. Remove demand valve assembly (5).

Demand valve assembly: 30 kg
INSTALLATION
removal.
• Refilling with oil (Hydraulic tank)

• Bleed air. For details, see TESTING AND

ADJUSTING, Bleeding air from hydraulic cylinder
(for steering).
30-132 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY HOIST VALVE

TION OF HOIST VALVE
ASSEMBLY
REMOVAL
pin.
1. Drain hydraulic oil.

Hydraulic tank: 122
2. Disconnect the tube and hose from the under-

side of hoist valve assembly (1).
3. Disconnect tubes (2), (3), and (4) and hose (5).
4. Hoist valve assembly (1).

Hoist valve assembly: 35 kg
INSTALLATION
removal.
• Refilling with oil (Hydraulic tank)

HD465-7, HD605-7 30-133

➂
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

BLY OF STEERING CYLIN-
DER ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-502-1003 Repair stand ■ 1
1
2 790-102-3802 Wrench assembly ■ 1
3 790-302-1270 Socket ■ 1
790-201-1702 Push tool kit ■ 1 4. Remove cylinder (4) from tool U1.
790-101-1771 • Push tool ■ 1
4 5. Disassembly of piston rod assembly
790-101-5021 • Grip ■ 1
1) Set tool U1 to piston rod assembly (3).
U 01010-50816 • Bolt ■ 1 2) Using tool U3, remove nut (5).
790-201-1500 Push tool kit ■ 1 ★ Width across flats of nut: 50 mm
790-101-1580 • Push tool ■ 1
5
790-101-5021 • Grip ■ 1
01010-50816 • Bolt ■ 1
6 790-720-1000 Expander ■ 1
7 796-720-1650 Ring ■ 1
8 07281-01029 Clamp ■ 1
DISASSEMBLY
1. Set cylinder assembly (1) to tool U1.
2. Raise the lock of the cylinder head nut. Using

tool U2, remove cylinder head assembly (2).
3) Remove piston assembly (6) and cylinder
head assembly (7) from rod (8).
3. Pull cylinder head and piston rod assembly (3)

out of cylinder (4).
★ Prepare a container to receive oil which flows
out when the piston rod assembly is pulled
out of the cylinder.
30-134 HD465-7, HD605-7

➂
6. Disassembly of piston assembly ASSEMBLY

1) Remove wear ring (9) from piston (10).
2) Remove piston ring (11) from piston (10). ★ Apply engine oil to the sliding surfaces of each
part. When assembling, take care not damage
the packing, dust seal, and O-ring.
1. Assembly of cylinder head assembly

1) Using tool U4, press fit bushing (15) to cylin-
der head (16).
★ When press fitting the bushing, take
extreme care not to deform it.
2) Install rod packing (14).
★ Install the rod packing as shown in the
following figure.
3) Install backup ring (18) and O-ring (17) in
order.
★ Do not install the backup ring forcibly.
Warm it in water at 50 – 60°C before
7. Disassembly of cylinder head assembly installing it.
1) Remove snap ring (12) and dust seal (13). 4) Using tool U5, install dust seal (13) to cylin-
2) Remove rod packing (14). der head (16), and then install snap ring (12).
3) Remove bushing (15) from cylinder head
(16).
4) Remove O-ring (17) and backup ring (18).
2. Assembly of piston assembly

1) Using tool U6, expand piston ring (11).
★ Set the piston ring to the tool and rotate
the handle 8 – 10 turns to expand the
piston ring.
2) Remove the piston ring from the tool and
install it to piston (10).
HD465-7, HD605-7 30-135

➃
3) Set tool U7. Using tool U8, shrink the piston 3) Remove piston rod assembly (3) from tool
ring. U1.
4) Install wear ring (9). 4. Set the cylinder to tool U1.
5. Install cylinder head and piston rod assembly (3)

to cylinder (4).
3. Assembly of piston rod assembly

1) Install cylinder head assembly (7) and piston
assembly (6) to piston rod (8).
6. Using tool U2, tighten cylinder head assembly
(2).
Cylinder head nut:
637.5 ± 63.7 Nm {65 ± 6.5 kgm}
2) Using tool U3, tighten nut (5).

Nut: Adhesive (Loctite No. 262)
Nut:
1,078.8 ± 107.9 Nm {110 ± 11.0 kgm}
★ Width across flats of nut: 50 mm
30-136 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER

BLY OF HOIST CYLINDER
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-502-1003 Repair stand ■ 1
1
2 790-102-3802 Wrench assembly ■ 1
3 790-720-1000 Expander ■ 1 3. Remove cylinder and rod assembly (3) from

cylinder (2).
4 796-720-1680 Ring (For cylinder ) ■ 1
Clamp
5 07281-01580 ■ 1
(For cylinder )
Push tool
792-201-7310 ■ 1
(For cylinder )
790-101-5421 Grip (For cylinder ) ■ 1
01010-81240 Bolt (For cylinder ) ■ 1

Push tool
6 790-201-1702 ■ 1
(For cylinder )
U
• Push tool
790-201-1851 ■ 1
(For cylinder )
• Grip
790-101-5021 ■ 1
(For cylinder )
• Bolt
01010-50816 ■ 1
(For cylinder )
792-201-7410 Plate (For cylinder ) ■ 1
4. Remove piston nut (4) and lift down rod (6) from
790-101-5021 Grip (For cylinder ) ■ 1
cylinder (5).
01010-80816 Bolt (For cylinder ) ■ 1
Push tool kit 5. Pull cylinder assembly (1) out of rod (6).
7 790-201-1500 ■ 1
(For cylinder )
• Plate
790-201-1660 ■ 1
(For cylinder )
• Grip
790-201-5021 ■ 1
(For cylinder )
• Bolt
01010-50816 ■ 1
(For cylinder )
DISASSEMBLY
• When disassembling, take care not to damage
the rod packing, dust seal, piston ring, wear ring,
etc.
1. Set the cylinder assembly to tool U1.
2. Using tool U2, remove cylinder head assembly

(1) from cylinde (2).
HD465-7, HD605-7 30-137

➂
6. Disassembly of cylinder head assembly ASSEMBLY

1) Remove snap ring (7) and dust seal (8) from
cylinder head assembly (1). ★ Check each part for dirt, flaw, etc. and apply
2) Remove rod packing (9) and bushing (10). engine oil to the sliding surfaces before assem-
3) Remove backup ring (11) and O-ring (12). bling.
1. Using tool U6, press fit bushing (21) to cylinder

(5).
7. Disassembly of piston assembly and cylin-

der
1) Remove wear ring (13).
2) Remove snap ring (14) and pull out piston 2. Install rod packing (20) to cylinder (5).
assembly (15). ★ Install the rod packing as shown in the fol-
3) Remove piston ring (16) and wear ring (17) lowing figure.
from piston assembly (15).
4) Remove snap ring (18) from cylinder (5), 3. Using too U7, install dust seal (19).
and then remove dust seal (19).
5) Remove rod packing (20) and bushing (21).
4. Install snap ring (18).
30-138 HD465-7, HD605-7

➂
5. Assembly of piston assembly 7. Install wear ring (13) to cylinder (5).

1) Using tool U3, expand piston ring (16) and
install it to piston (15).
★ Set the piston ring to tool U3 and rotate
the handle 8 – 10 turns to expand the
piston ring.
2) Set tool U4. Using tool U5, shrink piston ring
(16).
8. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (10).
3) Install wear ring (17).
9. Install rod packing (9) to cylinder head (1).

★ Install the rod packing as shown in the fol-
lowing figure.
6. Install piston assembly (15) to cylinder (5),

and then install snap ring (14).
HD465-7, HD605-7 30-139

➂
10. Using tool U7, install dust seal (8).
11. Install snap ring (7), O-ring (12), and backup ring 15. Install cylinder and rod assembly (3) to cylin-
(11). der (2).
12. Install head assembly (1) to rod (6). 16. Using tool U2, tighten cylinder head assembly
(1).
13. Sling rod (6) and install it to cylinder (5).
Cylinder head assembly:
★ Align the bolt holes of the piston assembly
1,569.1 ± 156.9 Nm {160 ± 16 kgm}
and rod.
14. Tighten piston mounting nut (4).

★ Degrease the fitting parts of the bolt and nut
sufficiently.
★ Width across flats of bolt: 24 mm
Threads of piston rod:
Adhesive (Loctite No. 262)
Mounting nut:
274 ± 27.4 Nm {28 ± 2.8 kgm}
30-140 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY DUMP BODY
REMOVAL AND INSTALLA- 5. Lift off dump body assembly (5).

TION OF DUMP BODY Dump body assembly
HD465-7: 10,750 kg
Special tools HD605-7: 13.450 kg
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
V1 790-441-1320 Hook ■ 4
REMOVAL
ing brake switch to the PARK position, then put
blocks under the wheels.
1. Using tool V1, sling the dump body assembly

temporarily by 4 points.
•
2. Remove hoist cylinder bottom pin (1) and fix it
with a lever block, etc. so that hoist cylinder (2)
will not fall down.
3. Disconnect body positioner rod (3) from the

body.
4. Remove body hinge pins (4) on both sides.

★ Check the thickness, quantity, and location of
the shims.
HD465-7, HD605-7 30-141

➂
INSTALLATION
removal.
When aligning the pin holes, never insert

your fingers in them.
Bottom pin:
157 – 196 Nm {16 – 30 kgm}
★ Adjust the body positioner sensor. For

details, see TESTING AND ADJUSTING,
Adjusting body positioner sensor. 1. Adjust the shim of the dump body bottom mount.
1) Insert spacer 29 mm thick [1] at the end of
dump body (5) (1 each on both sides).
★ Install the shims as removed. 2) Measure clearance x between the center of
installing part of bottom mount (6) and top of
When aligning the pin holes, never insert
rear frame (7).
your fingers in them.
★ Measure the clearance at parts A, B, and
Hinge pin: C, 6 parts in total on both sides.
245 – 309 Nm {25 – 31.5 kgm} 3) Calculate the respective shim thicknesses
for 6 parts of A, B, and C on both sides.
• Shim thickness = (x – 26) mm
After installing the dump body assembly, devia- 4) Set shims (8) calculated in 3) above to the
tion z of the dump body assembly from the cab bottom mount (6).
assembly is in the following range. • Standard shim thickness: 3 mm
• Standard range of dimension z: 58 ± 12 mm • Thicknesses of shims: 1 mm, 3.2 mm
5) Remove spacer [1] and lower the dump body
and check that the all 6 parts of A, B, and C
of the bottom mount are in contact with the
top of the rear frame.
★ If dimension z is out of the standard range,

adjust it with shims (11) of body hinge pins
on both sides.
• Thicknesses of shims: 1 mm, 6 mm
30-142 HD465-7, HD605-7

➂
2. After adjusting the shims on the bottom mount,

adjust the shims on the left front mount.
1) Lower the dump body and measure thick-
ness Y of pad (9).
• Standard thickness Y : 50 mm
2) If the pad thickness exceeds 50 mm or there
is a clearance between the dump body and
pad, add shim (10) to adjust the pad thick-
ness properly.
HD465-7, HD605-7 30-143

!
DISASSEMBLY AND ASSEMBLY OPERATOR'S SEAT
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT

ASSEMBLY
! The procedure for disassembling and assembling the operator's seat assembly (air suspension (ISRING
HAUSEN)) is shown below.
A: Headrest E : Left-hand armrest

B: Seatback F : Suspension cover
C: Seat cushion G : Rails
D: Right-hand armrest
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the positions of
the 2 clips (2) of headrest stay (1) on both
sides.
30-144 HD465-7, HD605-7

(7)
2) Apply force b to part a of each clip (2) in the 2. Seatback

direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear left
Release headrest stay (1) from part d of the of seatback (4).
clip and pull out up headrest (3). ★ Before disconnecting the air hoses, check
their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
★ Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HD465-7, HD605-7 30-145

➃
4) Apply force E to the right side of seatback (4) 2) Push cushion stopper wire (9) down with
in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and remove
right side up. it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion • The procedure for disassembling right-hand arm-
1) Push cushion adjuster lever (7) inward and rest (10) is shown below. (Disassemble left-
slide seat cushion (8) to the front end. hand armrest (11) similarly.)
30-146 HD465-7, HD605-7

➃
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. ★ There are 2 position adjustment washers
★ Use a flat-head screwdriver, etc. to (16) installed to each bolt between the
remove the cap. armrest and seatback. Take care not
2) Loosen armrest hinge mounting bolt (13). lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of right- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear with
screwdriver [1], etc.
★ Take care not to damage the plastic plate
by prying it off forcibly with a screwdriver,
etc.
4) Turn right-hand armrest (10) up by 180

degrees.
★ If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mounting
bolt (15B)
HD465-7, HD605-7 30-147

➃
3) Remove 4 suspension cover fixing rings (19). 6) Remove 6 plastic suspension cover clips
(small) (25) and 2 plastic suspension cover
clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
★ If you remove the suspension cover with-
out performing the work in steps 5) and
6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear

fixing plate (21), 2 cushion rails (22), and 4
bushings (23).
6. Rails
1) Turn over the seat assembly to set rails (28)
on the upside.
5) Remove 3 metallic suspension cover clips

(24).
30-148 HD465-7, HD605-7

➃
2) Slide rails (28) to the rear end. ASSEMBLY

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of 1. Rails
each rail. 1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part of 2) Set rails (28) to the front end and install 1
each rail, and then remove rails (28). lock washer (30) and 1 hexagon socket head
bolt (29) to each rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
★ Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
3) Set rails (28) to the rear end and install 1 lock
washer (30) and 1 hexagon socket head bolt
(29) to each rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HD465-7, HD605-7 30-149

➃
2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails (22),

1) Set suspension cover (27) in position and and then install cushion rear fixing plate (21),
install 6 plastic suspension cover clips and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension cover Cushion rail mounting bolt:
clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
2) Install 3 metallic suspension cover clips (24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
30-150 HD465-7, HD605-7

➃
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

• The procedure for assembling right-hand arm- ★ Tighten the bolt so that the arm will move
rest (10) is shown below. (Assemble left-hand smoothly.
armrest (11) similarly.) • Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for

each bolt and set right-hand armrest (10) in
position. 4. Seat cushion
1) Slide in the seat cushion from the front of the
fitting position.
★ If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly and

turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
mounting bolt (15A) permanently.
Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
HD465-7, HD605-7 30-151

➃
5. Seatback 3) Connect 3 air hoses (5) to the rear left of the

1) Insert the left side of seatback (4), and then seatback (4).
lower and set the right side.
6. Headrest
1) Insert headrest (3) in seatback (4).
★ Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6) (M8

bolt).
Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
30-152 HD465-7, HD605-7

➃
90 OTHERS
Power train hydraulic circuit diagram ...................................90- 2

Steering and hoist hydraulic circuit diagram.........................90- 3
Brake hydraulic circuit diagram ............................................90- 5
Electrical circuit diagram (1/6) ..............................................90- 7
Electrical circuit diagram (2/6) ..............................................90- 9
Electrical circuit diagram (3/6) ..............................................90-11
Electrical system diagram related to transmission control ...90-19
Electrical system diagram related to monitor .......................90-21
HD465-7, HD605-7 90-1

➁
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HD465-7, HD605-7

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HD465-7, HD605-7 90-3

BRAKE HYDRAULIC CIRCUIT DIAGRAM
HD465-7, HD605-7 90-5

ELECTRICAL CIRCUIT DIAGRAM (1/6)
HD465-7, HD605-7 90-7

HD465-7, HD605-7 90-9

HD465-7, HD605-7 90-11

HD465-7, HD605-7 90-13

HD465-7, HD605-7 90-15

HD465-7, HD605-7 90-17

ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
HD465-7, HD605-7 90-19

(7)
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
HD465-7, HD605-7 90-21

(7)

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SEBM027609

MACHINE MODEL SERIAL NUMBER

HD465-7 7001 and up

• HD465-7, HD605-7 mount the SAA6D170E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ............................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1

90 OTHERS ............................................................................................................................... 90-1

00-2 HD465-7, HD605-7

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

HD465-7, HD605-7 00-2-1

00-2-2 HD465-7, HD605-7

HD465-7, HD605-7 00-2-3

00-2-4 HD465-7, HD605-7

HD465-7, HD605-7 00-2-5

Specification drawings....................................... 01- 2

HD465-7, HD605-7 01-1

01-2 HD465-7, HD605-7

Machine model HD465-7

Serial No. 7001 and up

Max. load kg 55,000

(front) kg 20,120 (47%)

(rear) kg 22,680 (53%)

(front) kg 31,320 (32%)

Max. travel speed km/h 70

Min. turning radius m 8.5

Overall length mm 9,355

Overall width mm 4,595

Overall height mm 4,400

Wheel base mm 4,300

Front wheel mm 3,515

Ground clearance mm 645

Model KOMATSU SAA6D170E-3

Type 4-cycle, water-cooled, in-line 6-cylinder,

Rated output kW/rpm{HP/rpm} 533/2,000 {715/2,000}

HD465-7, HD605-7 01-3

Machine model HD465-7

Serial No. 7001 and up

Structure 3-element, 1-stage, 2-phase

TORQFLOW planetary gear

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

Type Fully hydraulic steering system

Front axle Independent suspension (Mac Pherson type)

Front axle Hydropneumatic

Front tire 24.00 – 35 – 36PR × 2

Rear tire 24.00 – 35 – 36PR × 4

Front wheel Single dry disc type, Hydraulically controlled

Rear axle Oil cooled multiple disc brake, Hydraulically controlled

Parking brake Multiple disc wet type disc brake,

Retarder Oil cooled multiple disc type, Hydraulically controlled

01-4 HD465-7, HD605-7

Machine model HD465-7

Serial No. 7001 and up

For both steering and work equipment

Type Gear pump

Delivery /min 348

For charging torque converter