Shop Manual HD465-7 Dan HD 605-7

SEBM027600
MACHINE MODEL SERIAL NUMBER
HD465-7 7001 and up

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

For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2002
All Rights Reserved
Printed in Japan 07-02(02) 00-1
➀
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 .......................................... Will be issued later
90 OTHERS ............................................................................................................................... 90-1
00-2 HD465-7, HD605-7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

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

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

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

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

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

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

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

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

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

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 0
8 2 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

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

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
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

MAINTENANCE STANDARD
Radiator, torque converter oil cooler, after cooler, Proportional reducing valve ......................... 10-75
work equipment oil cooler, fuel cooler ......... 10- 3 Parking brake solenoid valve....................... 10-76
Brake oil cooler............................................ 10- 4 Suspension.................................................. 10-78
Power train skeleton.................................... 10- 5 Suspension cylinder .................................... 10-80
Output shaft................................................. 10- 6 Steering and hoist hydraulic piping.............. 10-86
Torque converter and transmission hydraulic Dump body control ...................................... 10-88
piping......................................................... 10- 8 HYdraulic tank ............................................. 10-89
Torque converter ......................................... 10-10 Steering and hoist hydraulic system
Transmission ............................................... 10-18 diagram...................................................... 10-90
Transmission valve...................................... 10-27 Steering control valve .................................. 10-92
E-POCV ...................................................... 10-28 Crossover relief valve .................................. 10-96
Drive shaft ................................................... 10-38 Steering cylinder .......................................... 10-97
Axle ............................................................. 10-40 Demand valve.............................................. 10-98
Differential ................................................... 10-42 Hoist valve ................................................. 10-102
Final drive.................................................... 10-44 EPC valve.................................................. 10-108
Wheels ........................................................ 10-46 Hoist cylinder ............................................. 10-109
Rear axle support ........................................ 10-48 Hydraulic pump.......................................... 10-110
Steering column........................................... 10-50 Air conditioner............................................ 10-114
Steering linkage........................................... 10-51 Machine monitor system............................ 10-119
Brake piping ................................................ 10-54 Engine control system ............................... 10-134
Brake valve.................................................. 10-56 Automatic shift control system ................... 10-136
Accumulator charge valve ........................... 10-59 Automatic suspension system ................... 10-148
Emergency brake valve............................... 10-63 Payload meter (card type)...................... 10-151
Relay valve.................................................. 10-64 Automatic emergency steering system...... 10-184
Front brake off valve.................................... 10-65 Sensors, switches...................................... 10-188
Accumulator ................................................ 10-66 Retarder control system ............................ 10-196
Slack adjuster.............................................. 10-67 Dump control lever .................................... 10-208
Brake ........................................................... 10-70
HD465-7, HD605-7 10-1

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

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

TORQUE CONVERTER AND
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
1. When the lock-up clutch is [RELEASED] 2. 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

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

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
1. 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.
2. 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

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E-POCV
E-POCV (ELECTRONIC PILOT OPERATING CONTROL 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

E-POCV 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. • When the torque converter is operating without
Since the modulation actuates as shown below, lockup, no current is flowing to the proportional
the valve enables to engage the lockup clutch solenoid (1).
smoothly and to reduce shocks at the time of The pressure control valve (3) drains oil from the
gearshift. Also, the valve prevents the power clutch port A through the drain port Dr, and the
train from causing peak torque. This improves lockup clutch is [RELEASED]. Since oil pressure
operator comfort and makes the power train force does not work to the pressure detection
more durable. valve (4), the fill switch (6) is turned OFF.
HD465-7, HD605-7 10-29

WHEN THE TORQUE CONVERTER IS

OPERATING WITH LOCKUP
(Torque converter operation with lockup :
Lockup operation)
1. At filling time 2. 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 (6) 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

E-POCV FOR SPEED RANGE CLUTCH

Outline of E-POCV E-POCV and Proportional Solenoid
• The E-POCV (Electronic-pilot Operating Control • A proportional solenoid is mounted on the E-
Valve) is composed of a pressure control valve POCV.
and a fill switch. By the command current from the controller, the
• Pressure Control Valve solenoid generates thrust as shown in the figure
This valve converts the current which flows from below:
the transmission controller to the proportional
solenoid, into oil pressure. Thrust generated by the proportional solenoid
• Fill Switch works to the pressure control valve spool. Then
This switch detects that oil is filled fully in the oil pressure is generated as shown in the figure
clutch, and also has the following functions. below. So, as the command current is con-
1) When the clutch is filled fully with oil, the trolled, thrust changes, the pressure control
valve outputs a signal (fill signal) to the con- valve is actuated and oil flow and oil pressure
troller to inform the end of filling. are controlled.
2) While the clutch is under oil pressure, the
valve outputs a signal (fill signal) to the con-
troller to inform existence or non-existence of
oil pressure.
Area A: Before gear shift (at the time of draining)

Area B: Start of filling (in trigger)
Area C: End of filling
Area D: Pressure is being adjusted
Area E: Under filling
E-POCV and Fill Switch

• A fill switch is mounted on the E-POCV.
When the clutch completes filling with oil, the
pressure in the clutch turns on the fill switch. By
this signal, the oil pressure starts buildup.
HD465-7, HD605-7 10-31

Operation of E-POCV
• The E-POCV is controlled by command current 1. Before gear shift (at the time of draining)
from the controller to the proportional solenoid (Area A in diagrams)
and by signals output from the fill switch. When no current is supplied to the proportional
Relations for the E-POCV among proportional solenoid (1), the pressure control valve (3) is
solenoid command current , clutch input pres- draining oil from the clutch port A through the
sure and fill switch output signal are as shown in drain port Dr.
the figures below: Since no oil pressure works to the pressure
detection valve (4), the fill switch (6) is OFF.
Area D: Pressure adjustment
10-32 HD465-7, HD605-7

2. At Filling Time (When a trigger command is 3. Pressure Adjustment (Area D in Diagrams)

input to the pressure control valve) When a current is supplied to the proportional
(Areas B and C in Diagrams) solenoid (1), the solenoid generates a thrust in
When any current is supplied to the proportional proportion to the current. The solenoid thrust,
solenoid (1) and when the clutch contains no oil, and the sum of the clutch port thrust by oil pres-
an oil pressure balancing with the solenoid force sure and bouncing force of the pressure control
works to Chamber B and pushes the pressure valve spring (2) is balanced for adjusting pres-
control valve (3) to the left. Then, the pump port sure.
P and the clutch port A open, the valve starts fill-
ing the clutch with oil, and when the clutch fills
with oil, the fill switch (6) is turned ON.
HD465-7, HD605-7 10-33

(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

E-POCV FOR SPEED RANGE CLUTCH

Outline of E-POCV E-POCV and Proportional Solenoid
• The E-POCV (Electronic-pilot Operating Control • A proportional solenoid is mounted on the E-
Valve) is composed of a pressure control valve POCV.
and a fill switch. By the command current from the controller, the
• Pressure Control Valve solenoid generates thrust as shown in the figure
This valve converts the current which flows from below:
the transmission controller to the proportional
solenoid, into oil pressure. Thrust generated by the proportional solenoid
• Fill Switch works to the pressure control valve spool. Then
This switch detects that oil is filled fully in the oil pressure is generated as shown in the figure
clutch, and also has the following functions: below. So, as the command current is con-
1) When the clutch is filled fully with oil, the trolled, thrust changes, the pressure control
valve outputs a signal (fill signal) to the con- valve is actuated and oil flow and oil pressure
troller to inform the end of filling. are controlled.
2) While the clutch is under oil pressure, the
valve outputs a signal (fill signal) to the con-
troller to inform existence or non-existence of
oil pressure.

Area D: Pressure is being adjusted
E-POCV and Fill Switch

• A fill switch is mounted on the E-POCV.
When the clutch completes filling with oil, the
pressure in the clutch turns on the fill switch. By
this signal, the oil pressure starts buildup.
HD465-7, HD605-7 10-35

Operation of E-POCV
• The E-POCV is controlled by command current 1. Before gear shift (at the time of draining)
from the controller to the proportional solenoid (Area A in diagrams)
and by signals output from the fill switch. When no current is supplied to the proportional
Relations for the E-POCV among proportional solenoid (1), the pressure control valve (3) is
solenoid command current , clutch input pres- draining oil from the clutch port A through the
sure and fill switch output signal are as shown in drain port Dr.
the figures below: Since no oil pressure works to the flow detection
valve (4), the fill switch (5) is OFF.
Area D: Pressure adjustment
10-36 HD465-7, HD605-7

2. At Filling Time (When a trigger command is 3. Pressure Adjustment (Area D in Diagrams)

input to the pressure control valve) When a current is supplied to the proportional
(Areas B and C in Diagrams) solenoid (1), the solenoid generates a thrust in
When any current is supplied to the proportional proportion to the current. The solenoid thrust,
solenoid (1) and when the clutch contains no oil, and the sum of the clutch port thrust by oil pres-
an oil pressure balancing with the solenoid force sure and bouncing force of the pressure control
works to Chamber B and pushes the pressure valve spring (2) is balanced for adjusting pres-
control valve (3) to the left. Then, the valve sure.
starts filling the clutch chamber with oil from the
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

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).
10-38 HD465-7, HD605-7

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
10-40 HD465-7, HD605-7

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 REAR AXLE SUPPORT
REAR AXLE SUPPORT
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
10-48 HD465-7, HD605-7

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 10-49

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
10-50 HD465-7, HD605-7

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 10-51

10-52 HD465-7, HD605-7

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 10-53

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-54 HD465-7, HD605-7

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 10-55

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
10-56 HD465-7, HD605-7

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 10-57

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.
10-58 HD465-7, HD605-7

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 10-59

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

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-60 HD465-7, HD605-7

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 10-61

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.
10-62 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY BRAKE VALVE
EMERGENCY BRAKE VALVE
1. Rod Function
2. Spool • When the pedal is stepped down, the parking
3. Cylinder brake release pressure decreases. This valve
operates the parking brake depending on pedal
A : To parking brake valve angle.
P : From accumulator
HD465-7, HD605-7 10-63

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
10-64 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FRONT BRAKE OFF VALVE
FRONT BRAKE OFF VALVE
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 10-65

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}
10-66 HD465-7, HD605-7

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}
HD465-7, HD605-7 10-67

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.
10-68 HD465-7, HD605-7

A
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE
BRAKE
FRONT
1. Piston
2. Pad
3. Disc
10-70 HD465-7, HD605-7

Unit: mm
Wear of pad (remaining thick- Standard size Repair limit

4
ness of wear material) Replace
19.5 3.0
5 Missing portion of pad – Ratio of surface: 10%
Correct of
6 Face runout of disc (Note 1) 0.15 0.50
replace
Wear of disc
7 30 Less than 27
(thickness of disc)
Replace
Open crack in radial direction
8 Damage to disc surface –
Electric wear, marked damage (Note 2) Correct
Note 1: • If there is excessive face runout of the disc, check the front wheel bearing also.
Note 2: • If the depth of the scratch exceeds 1.5 mm.
• If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or
there is protrusion.
• If there are vertical scratches other than concentric scratches.
HD465-7, HD605-7 10-71

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)
10-72 HD465-7, HD605-7

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 10-73

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.
10-74 HD465-7, HD605-7

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 10-75

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.
10-76 HD465-7, HD605-7

A
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
10-78 HD465-7, HD605-7

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 suspen-
sion cylinders. It is connected to these at both
ends by spherical bearings. It transmits the load
and motive force through the top and bottom
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 10-79

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
10-80 HD465-7, HD605-7

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 10-81

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.
10-82 HD465-7, HD605-7

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 9JY01206
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 10-83

REAR
1. Feed valve
2. Cylinder
3. Rod
4. Air bleeding valve
5. Ball
10-84 HD465-7, HD605-7

Unit: mm

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

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

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(6) through orifices (4) and (5) to cavity (2), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
a) Retracting action
When the machine is traveling and it hits a bump
or object on the road, the wheels are pushed up,
and the cylinder rod is pushed inside the cylin-
der.
When this happens, the nitrogen gas inside
chamber (7) is compressed, the oil in chamber
(6) is sent through both orifices (4) and (5) to
cavity (2), and cavity (2) is filled more quickly
than when extending.
b) Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil remain-
ing 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 10-85

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

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

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.
10-88 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Breather
2. Drain
3. Oil level gauge
HD465-7, HD605-7 10-89

STEERING AND HOIST HYDRAULIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SYSTEM DIAGRAM
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
10-90 HD465-7, HD605-7

STEERING AND HOIST HYDRAULIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SYSTEM DIAGRAM
HD465-7, HD605-7 10-91

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
Crearance 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
Crearance between piston rod +0.039

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

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

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

2 100 0.693
andd bushing –0.123 +0.067 0.393
Crearance between piston rod +0.004

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

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

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 Delivery
delivery
Model speed pressure amount limit
amount
Discharge amount (rpm) MPa {kg/cm2} (l/min)
–
(l/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
retuned to the compressor.
10-114 HD465-7, HD605-7

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

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
transmit that data as network data to the This changes the original setting for the
machine monitor. replacement interval.
• The machine monitor is a system to display 6. Controller initialize
these data and inform the operator of the condi- This function is used to set the machine
tion of the machine. monitor when the machine is shipped from
• There are two types of display on the machine the factory.
monitor: the normal mode and the service mode.
• The items that are always displayed for the oper- The service mode has the following functions.
ator are the normal mode items. Their main con- Setting service meter
tent is as follows. • This can set service meter values recorded
1. Normal display items in machine monitor memory
• Meters (speedometer, tachometer) • However, values can only be increased from
• Gauges (engine water temperature, present value (they cannot be decreased).
torque converter oil temperature, retarder
oil temperature, fuel level) Setting total travel distance
• Pilot display • This can set travel distance values recorded
• Service meter, odometer (character dis- in machine monitor memory
play) • However, values can only be increased from
2. Items displayed when there is abnormality present value (they cannot be decreased).
Caution, action code display (if an action code
is being displayed, press machine monitor Setting distance traveled in reverse
mode selector switch (2), then release it. A • This can set values for distance traveled in
failure code (6-digit) is then displayed.) reverse recorded in machine monitor mem-
3. When the filter, oil replacement interval is ory.
reached, the item needing replacement is • However, values can only be increased from
displayed in the character display. present value (they cannot be decreased).
4. Other functions using the character display
and the machine monitor mode selector • The machine monitor system consists of the
switch to operate include the following: Total monitor panel, buzzer, and switches, network,
reverse distance traveled display, filter, oil controllers on the network, and the sensors
replacement interval reset, telephone num- inputting data to the monitor panel.
ber input, and language selection.
• To make it easier to carry out troubleshooting of

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

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 prepalation 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

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 lighted up while the machine monitor check switch is ON.
✩2: The mark shows that all lights are lighted 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 lighted up dur-

Backlight LED Amber small lamp is ing operation — —
lighted 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
lighted up. starting position.
When the Lighted up

Backlight LED Amber small lamp is during — —
lighted up. operation

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)
color: starting from the
Oil tem- black current position
3 perature andreturn to the
9 of starting position.
retarder
Lighted up
Warning LED Red At 120°C during being
or higher abnormal
When the Lighted up
Backlight LED Amber small lamp is during — —
lighted up. operation.

the machine
Gauge ment ground (120°C or higher display — — — forth one time, as
color: in the red zone) (Note)
starting from the
Oil tem- black current position
4 perature and return to the
10 of torque starting position.
converter
At 120°C Lighted up
Warning LED Red or higher during being
abnormal
When the Lighted up
Backlight LED Amber small lamp is during  
10-124 HD465-7, HD605-7

Related When
operation machine
monitor Immedi-
No. Display Display Device Color Display range/ Display check ately Remarks
item category conditions method Central switch is after
warn- Warn- turning
ing oper-
ing ated. key ON.
lamp buzzer
the machine
Gauge ment ground (102°C or higher display    forth one time, as
in the red zone) (Note)
Engine color: starting from the
water black current position
5 and return to the
tempera-
11 ture starting position.
Lighted up
Warning LED Red At 102°C or during being
higher abnormal
When the Lighted up
Backlight LED Amber small lamp is during  
the machine
Gauge Move- Back- EMPTY – FULL Analog    knob back and
ment ground display (Note) forth one time, as
color: starting from the
and return to the
6 Fuel starting position.
12 level
Specified level
or less Lghted up
Warning LED Red (remaining quan- during opera-  
tity in the tank at tion
120 or less)
When the small Lighted up
Backlight LED Amber lamp is lighted during opera-  
up. tion.
Service 0 – 65535.0h Operates

when the
meter
Service * Displayed in the engine is
When 65535.0h is
(Regular "upper column" — — exceeded, fixed at
display meter running. 65535.
on the character 1:1 against
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
When any prob- failure occurs, Note 1:"HD-465" is dis-
lem or failure the action played in the
Display 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
and remedies upper column
ground upper and lower and "SYSTEM
color: columns on the or description
of problem in CHECK" in the
green character display. 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
displayed in For information on how
Problem Problem lem or to operate display, see
failure on the the upper col- — —
code code umn and the the instruction manual.
machine.
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

Related When
operation machine Immedi-
monitor ately
No. Display Display Device Color Display range/ Display check after Remarks
item category conditions method Central switch is turning
warn- Warn- oper- key ON.
ing 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 change fil- LCD Back- selector switch monitor mode For details, see the
displays ter and oil. ground selector instruction manual.
" "
Telephone color: switch
7 number green ">" or "<".
setting
Language
selection
Dimmed down
When the by a step
Night Backlight LED Green small lamp is when the — —
lighting lighted up. small lamp is
lighted up.
Central Lighted up
8 warning LED Red During system is during being
lamp abnormal abnormal.
Note 1:The moment

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

Related When
operation machine Immedi-
monitor ately
No. Display Display Device Color Display range/ Display check after Remarks
item category conditions method Central switch is turning
warn- Warn- oper- key ON.
ing ing
ated.
lamp buzzer
Trans-
Being abnormal Llighted up
mission
21 LED Red in transmission during being
system
control system abnormal.
warning
During being
Retarder Lighted up
abnormal in
22 system LED Red during being
retarder control
warning abnormal.
system
When the body is
Inclina- Lighted up
lifted and inclined
23 tion LED Red during being
excessively
warning Warning abnormal.
from side to side.
During
operation:
Seat-
When the seat- lighted up
24 belt LED Red — —
belt is not worn. During non-
warning
operation:
turned OFF.
During
operation: Note: Operates when
Body See the lighted up the shift lever is in
25 LED Red instruction During non- other than the "N"
warning manual (Note) (Note)
operation: position.
turned OFF.
During
Emer- When the emer- operation:
26 gency LED Red gency steering is lighted up  
steering operated. During non-
operation:
turned OFF.
During
Turn operation:
27 signal, LED Green During operation lighted up — —
During non-
right operation:
turned OFF.
During
Turn operation:
28 signal, LED Green During operation lighted up — —
During non-
left operation:
turned OFF.
During
Head- operation:
light, lighted 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" Lighted 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" Lighted up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lighted up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift * Blinks when the neu-
lever
position
LED Green lever is in the "6" Lighted up (*) — —
(6) position tral safety is operated.
6
Shift
30 When the shift
lever
LED Green lever is in the "5" Lighted up (*) — — * Blinks when the neu-
(5) position tral safety is operated.
position
5
HD465-7, HD605-7 10-127

Related opera- When

tion machine Immedi-
Display Display Display range/ Display monitor ately
Central switch is turning
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Shift
30 When the shift * Blinks when the neu-
lever
LED Green lever is in the "4" Lighted up (*) — —
(4) position position tral safety is operated.
4
Shift * Blinks when the neu-
30 When the shift
lever
LED Green lever is in the "3" Lighted up (*) — — tral safety is operated.
(3) position position
3
30 When the shift
lever
LED Green lever is in the "2" Lighted up (*) — — tral safety is operated.
(2) position position
2
30 When the shift
lever
LED Green lever is in the "L" Lighted 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 All
indicator color: is raised in the received lighted lighted
31 gray event of from the up. up.
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. lighted up
During
operation:
When the
lighted up
32 Retarder LED Orange retarder brake is — —
During non-
operated.
operation:
turned OFF
During
When lockup of
operation:
the torque con-
lighted 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 lighted up — —
(power mode
During non-
mode)
operation:
turned OFF
Economy
Output mode
mode in operation:
At economy
35 (econ- LED Green lighted up — —
mode
omy During non-
mode) operation:
turned OFF
Sus-
pension
At suspension Lighted up in
36 mode LED Green — —
"hard" mode "hard" mode
(hard)
(option)
10-128 HD465-7, HD605-7

Related opera- When

tion machine Immedi-
Display Display Display range/ Display monitor ately
Central switch is turning
warn- Warn-
ing oper- key ON.
ing ated.
lamp buzzer
Suspen-
sion Lighted up in
In suspension
37 mode LED Green "medium" — —
"medium" mode
(medium) mode
(option)
Suspen-
sion
In suspension Lighted up in
38 mode LED Green — —
"soft" mode "soft" mode
(soft)
(option)
During
operation:
ABS When ABS is
lighted up
39 (option) LED Orange operated. — —
During non-
operation:
turned OFF
During
operation:
When ASR is
ASR lighted up
40 LED Orange operated.
(option) During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lighted 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.
lighted up
ready
Auto-
Back- * Zero is displayed
matic When automatic Display of set
ground
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 lighted 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 lighted 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

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) E-POCV 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) Controller initialize
This function is used only at the factory, so
do not touch it.
7) 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.
8) 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.
9) 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

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

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 Idring Setting system)
Outline
• The AISS is a system which sets the engine low
idring 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

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 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
10-148 HD465-7, HD605-7

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 10-149

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.
PAYLOAD METER BLOCK DIAGRAM
10-150 HD465-7, HD605-7

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 detection switch • 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 load on
5. Pressure sensor (for front right) the springs of the machine.
6. Pressure sensor (for rear left) The measurement of the payload is obtained by
7. Pressure sensor (for rear right) calculating the difference between the load when
8. Suspension cylinder empty and the load when full.
9. Payload meter Payload meter displays the load calculated
10. Lamp drive relay above on the monitor screen and displays the
11. External display lamp load level on the external display lamps.
12. Battery The payload, distance, time, time engine was
13. Fuse (for external display lamp) turned ON/OFF, time of occurrence/cancellation
14. Fuse (for controller) of abnormalities or warnings, and other data are
15. Memory card automatically saved in memory. These data can
16. Travel signal sensor be later transmitted to a PC or written to a mem-
17. RS232C output (PC cable communication) socket ory card.
18. Battery charge signal (alternator terminal R) It also has an estimation display function: when
loading the next load, the new total load is esti-
mated and the appropriate lamp flashes. This
prevents overloading.
HD465-7, HD605-7 10-151

PRINCIPLE OF CALCULATION
1. Outline
The dump truck is supported by four suspension
cylinders. By measuring the total for the loads
bearing on each cylinder, it is possible to know
the load on the springs of the machine.
The payload can be calculated by subtracting the
unladen machine weight from the laden machine
weight.
The load on each cylinder can be calculated
from the cross-sectional area and internal pres-
sure of 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

2. Calculation of unladen weight (calibration)

The unladen weight is measured by calculating
the average load when the dump truck travels
unloaded for approx. 30 seconds on flat level
ground at a speed of approx. 10 km/h.
The measurement is carried out while traveling
because when the machine is traveling it is pos-
sible to cancel the sliding resistance of the sus-
pension cylinder by extending and retracting the
cylinder give an average over a period of time.
The measured unladen weight is stored in the
memory inside the controller as calibration data.
3. Measuring payload
The weight when the load is loaded is measured.
Loading is carried out with the shift lever at N,
the body control lever at FLOAT, and the
machine at a front-to-rear angle of within ± 5°.
4. Compensating on slopes
When loading is carried out on slopes, the
weight of the load is different from the value
measured on flat ground, so the front-to-rear
angle of the machine is detected and compensa-
tion is carried out according to the angle. (Angle
colmensation within ± 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

FEATURES OF EACH DEVICE

1. Payload meter
Payload meter uses the signals from the pres-
sure sensors, clinometer, body FLOAT detection,
shift lever (on payload meter II, this is the neutral
detection switch) as input, calculates the payload
using the built-in microcomputer, displays this on
the panel screen, and also displays the load level
on the external display 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

LEFT FACE
• Details of switches on left face
No. Name Type Remarks
–20% – +20%
1. Payload 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. Weight unit setting switch 2-stage selector switch Up : Metric ton Down : 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

• Table of model selector code
No. of model selector switches Model
0 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
• 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 (bottom)

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

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

ii) Measuring empty weight (calibration)

The weight 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 payload display level
for the external display lamps during the normal opera-
tion display.
The estimated display shows the estimation of the total
payload 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 Payload display (*1) Payload display

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

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

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

to time display
Loaded
Stopped N FLOAT Payload display Payload display
FLOAT→ Aggregate payload dis-

When dumping (*2) N RAISE → LOWER OFF
→ FLOAT play (*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 payload, display shows 0 ton.
(*2) For details of conditions taken as dumping, see v) Content of memory (1).
(*3) The aggregate payload display is shown in units of 100 ton. (Rounded to the nearest 100)
10-158 HD465-7, HD605-7

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

Maintenance Manual)
➀ 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

Payload MT OR ST 0-6553.5 
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
Limit speed km/h 0-99 Displays set value at time of dumping
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
 Average electric potential V 0-4.0  separately as spare signal input data.
Digital spare 1 
Lo frequency Times 0-255 
Digital spare 2 
Lo frequency Times 0-255 
(MT: Metric ton, ST: Short ton)
HD465-7, HD605-7 10-159

➁ 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 
Day Day 1-31  Shows when engine was switched OFF
Time Hour Hour Displayed as 0-23 
Aggregate payload MT OR ST 0-9999000  Total value between engine ON and engine
Total number of cycles Times 0-9999 
 OFF
➂ 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

➃ Data for aggregate payload, total number of cycles

★ It is possible to calculate and record again from any desired time the aggregate payload and total num-
ber of cycles for each time that the dumping conditions are fulfilled.
★ The calculation is started again for both values when the data for aggregate payload and total number of
cycles are cleared.
★ The maximum limit in memory for aggregate payload and total number of cycles is 999900.0 metric tons
or short tons and 9999 cycles respectively.
Item Unit Range
Aggregate payload MT OR ST 0-999900.0 Shows aggregate from time when data were
Total number of cycles Times 0-9999 cleared
Year (last 2 digits) Year 0-99

Month Month 1-12  Shows date and time when data were
Day Day 1-31 
Time Hour Hour Displayed as 0-23  cleared
➄ 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
Time Minute Minute 0-59
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

➅ 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) kg/cm2 0-6553.5 
Suspension pressure (front right) kg/cm2 0-6553.5 
Suspension pressure (rear left) kg/cm2 0-6553.5  Shows values before compensation

Suspension pressure (rear right) kg/cm2 0-6553.5  factor was calculated
Suspension load (front) MT 0-6553.5 
Suspension load (rear) MT 0-6553.5 
Tilt angle deg –9.99 – +9.99
Front wheel tilt compensation factor Integer 0-9.99999
Rear wheel tilt compensation factor Integer 0-9.99999
Front wheel link factor Integer 0-9.99999
Rear wheel link factor Integer 0-9.99999
Load on springs (empty) MT 0-6553.5
(MT: Metric ton)
➆ Payload calculation data (analog data)

★ These are saved in RAM when the payload calculation data are required.
★ The maximum limit in memory for payload 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
Time Minute Minute 0-59
Suspension pressure (front left) kg/cm2 0-6553.5
Suspension pressure (front right) kg/cm2 0-6553.5
Suspension pressure (rear left) kg/cm2 0-6553.5
Suspension pressure (rear right) kg/cm2 0-6553.5
Suspension load (front) MT 0-6553.5
Suspension load (rear) MT 0-6553.5
Tilt angle deg –9.99 – +9.99
Front wheel tilt compensation factor Integer 0-9.99999
Rear wheel tilt compensation factor Integer 0-9.99999
Front wheel link factor Integer 0-9.99999
Rear wheel link factor Integer 0-9.99999
Load on springs (empty) MT 0-6553.5
(Calibration value)
Trimmer gain value Integer 0.7500 –1.2500
Payload MT 0-6553.5
Backup battery voltage V 0-25.5
(MT: Metric ton)
The above data items ➀ – ➆ are retained even when the power is switched OFF.
10-162 HD465-7, HD605-7

vi) Forced display of aggregate payload, total num- x) Service check mode
ber 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 payload 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 payload.
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 payload setting when loading

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

Payload fixed display and cycle data recording,

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

recording
If the payload fixed display in Item 1) above is
applicable, it is possible to input and correct
the data to set the payload inside the cycle
data in Item 6-1 to the fixed display payload
value.
Possible set range: 00, 01, 10
Possible set value table
Display Payload fixed display Recorded payload value
00 Yes Payload 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 payload setting

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

Zero ton display range setting

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

This is used to input and correct the values
to set the lamp display payload range when
displaying the payload.
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 payload.
■ 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
• Payload 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

10-166 HD465-7, HD605-7

Operation for calibration data display
Set to CHEC display, then press From CALO flashing

Last 2 digits of year for date
switch for at least 2 seconds. when CAL was carried out
Month and day for date when
Display: CALO CAL was carried out
Hour and minute for date
when CAL was carried out
Model selection switch (decimal
value) when CAL was carried out
Every time the switch is pressed,
kg/cm2 P'FL (Front left)
the display changes in the order Suspension
shown on the right. kg/cm2 P'FR (Front right) pressure less than
100 kg/cm2: XX.X
kg/cm2 P'RL (Rear left) More than 100 kg/
cm2: XXX.X
If switch is pressed at any time
kg/cm2 P'RR (Rear right)
during the display in Steps or , the display
will return to CHEC. (End) ton Weight on front axle Less than 100 tons:
π 2
(= – D (P'FL+P'RL))
4 F
XX.X
ton Weight on rear axle More than 100 tons:
π 2 XXX.X
(= –
4 DR (P'RL+P'RR))
Appears when value is
Angle of tilt when CAL was negative
deg carried out ↓
(–) X.XX
Front axle tilt coefficient
Rear axle tilt coefficient

X.XXX
Front axle link coefficient
Rear axle link coefficient
Spring-up weight 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

Operation for payload calculation data (analog data) display
From ALLO flashing or A.FUL

Set to CHEC display, then press flashing
Hour, minute
switch for at least 2 seconds. kg/cm2 P'FL (Front left)

Suspension
Display: ALLO (when data in memory is kg/cm2 P'FR (Front right) pressure less than
less than 170 cycles) 100 kg/cm2: XX.X
kg/cm2 P'RL (Rear left) More than 100 kg/cm2:
A.FUL (when data in memory is XXX.X
more than 170 cycles) kg/cm2 P'RR (Rear right)
A.FUL (when data in memory is
ton Weight on front axle Less than 100 tons:
more than 180 cycles) (= –π4 D 2(P'FL+P'RL)) XX.X
F
More than 100 tons:
ton Weight on rear axle XXX.X
(= π–
4
D 2 (P'RL+P'RR))
R
Every time the switch is pressed, Appears when value is
Angle of tilt when CAL was negative
deg ↓
carried out
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
will return to CHEC. (End) Rear axle link coefficient
Spring-up weight calculated

ton according to calibration Same as and
— GT → Gain trimmer
ton Present payload 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

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

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
Set time: 1 seconds flow switch is acuated mistakenly by the pulse of the
oil ro fluttering of the flow switch.
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

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.
10-188 HD465-7, HD605-7

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 10-189

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.
10-190 HD465-7, HD605-7

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 10-191

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.
10-192 HD465-7, HD605-7

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 10-193

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.
10-194 HD465-7, HD605-7

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 10-195

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM
RETARDER CONTROL SYSTEM
10-196 HD465-7, HD605-7

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 10-197

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.
10-198 HD465-7, HD605-7

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
Pin
No. Specification Signal name Function Remarks
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 10-199

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
10-200 HD465-7, HD605-7

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 10-201

CN5
No.
1 Connector check 1 (to GND) CONNECTOR CHECK 2
2 D_IN_0 Pull up (5mA)
3 D_IN_1 Service brake switch Pull up (5mA) SERVICE BRAKE PRESS SW
4 D_IN_2 Retarder switch Pull up (5mA) RETARD BRAKE PRESS SW
5 D_IN_3 Parking brake switch Pull up (5mA) P/B, EMERG BRAKE PRESS SW
6 D_IN_4 Lever validation 1 switch Pull up (5mA) LEVER VARIDATION SW 1
7 D_IN_5 Lever validation 2 switch Pull up (5mA) LEVER VARIDATION SW 2
8 D_IN_6 — Pull up (5mA) SYSTEM FILTER
9 D_IN_7 Retarder cooling filter switch Pull up (5mA) RETARD COOLING FILTER
10 D_IN_8 — Pull up (8mA) —
11 D_IN_9 — Pull up (8mA) —
12 D_IN_10 Inclination switch Pull up (8mA) INCLINATION SW
13 D_IN_11 — Pull up (8mA) —
14 D_IN_12 — Pull up (8mA) —
15 D_IN_13 — Pull up (8mA) —
16 D_IN_14 — Pull up (8mA) —
17 D_IN_15 Memory clear switch Pull up (8mA) MEMORY CLEAR SW
18 D_IN_16 Engine starting signal Pull down KEY SW (E/G START SIGNAL)
19 D_IN_17 ABS signal Pull down COMMAND FROM ABS
20 D_IN_18 — Pull down —
Pull down/potentio power
21 D_IN_19 — —
+5V
22 D_IN_20 Brake wear sensor (left rear wheel) Pull up/down 1 BRAKE WEAR RL
23 D_IN_21 Brake wear sensor (right rear wheel) Pull up/down 1 BRAKE WEAR RR
Exhaust brake command EXHAUST BRAKE COMMAND
24 D_IN_22 Pull up/down 1
(from transmission controller) (FROM T/M)
Overrun prevention command OVERRUN COMMAND
25 D_IN_23 Pull up/down 1
(from transmission controller) (FROM T/M)
ASR actuating pressure switch
26 D_IN_24 Pull up/down 2 RL BRAKE PRESS SW (FOR ASR)
(left rear wheel)
ASR actuating pressure switch
27 D_IN_25 Pull up/down 2 RR BRAKE PRESS SW (FOR ASR)
(right rear wheel)
28 D_IN_26 — Pull up/down 2 —
10-202 HD465-7, HD605-7

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 10-203

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.
10-204 HD465-7, HD605-7

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 10-205

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 HOLD 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.
10-206 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-208 HD465-7, HD605-7

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 10-209

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.
10-210 HD465-7, HD605-7

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 • As a result, rod (2) is held at the pushed up posi-
down movement of the rod is output from poten- tion, so even if the lever is released, it is held at
tiometer (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 10-211

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 (3/6) ..............................................90-11
HD465-7, HD605-7 90-1

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HD465-7, HD605-7

SEBM027601
MACHINE MODEL SERIAL NUMBER
HD465-7 7001 and up

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

For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2002
All Rights Reserved
Printed in Japan 07-02(02) 00-1
➀
CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1

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

➀
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Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number number
" 00-1 # 10-4 10-48 10-91 10-132
" 00-2 # 10-5 10-49 10-92 10-133
! 00-2-1 # 10-6 10-50 10-93 10-134
! 00-2-2 # 10-7 10-51 10-94 10-135
! 00-2-3 # 10-8 10-52 10-95 10-136
! 00-2-4 # 10-9 10-53 10-96 10-137
00-3 10-10 10-54 10-97 10-138
00-4 10-11 10-55 10-98 10-139
00-5 10-12 10-56 10-99 10-140
00-6 10-13 10-57 10-100 10-141
00-7 10-14 10-58 10-101 10-142
00-8 10-15 10-59 10-102 10-143
00-9 10-16 10-60 10-103 10-144
00-10 10-18 10-61 10-104 10-145
00-11 10-19 10-62 10-105 10-146
00-12 10-20 10-63 10-106 10-147
00-13 10-21 10-64 10-107 10-148
00-14 10-22 10-65 10-108 10-149
00-15 10-23 10-66 10-109 10-150
00-16 10-24 10-67 10-110 10-151
00-17 10-25 10-68 10-111 10-152
00-18 10-26 10-70 10-112 10-153
00-19 10-27 10-71 10-113 10-154
00-20 10-28 10-72 10-114 10-155
00-21 10-29 10-73 10-115 10-156
00-22 10-30 10-74 10-116 10-157
10-31 10-75 10-117 10-158
01-1 10-32 10-76 10-118 10-159
01-2 10-33 10-78 10-119 10-160
01-3 10-34 10-79 10-120 10-161
01-4 10-35 10-80 10-121 10-162
01-5 10-36 10-81 10-122 10-163
01-6 10-37 10-82 10-123 10-164
01-7 10-38 10-83 10-124 10-165
01-8 10-40 10-84 10-125 10-166
01-9 10-41 10-85 10-126 10-167
01-10 10-42 10-86 10-127 10-168
01-11 10-43 10-87 10-128 10-169
10-44 10-88 10-129 10-170
10-1 10-45 10-89 10-130 10-171
10-3 10-46 10-90 10-131 10-172
HD465-7, HD605-7 00-2-1

➀
10-173 ! 20-105 # ! 20-156 # ! 20-301 # ! 20-352 #
10-174 ! 20-106 # ! 20-157 # ! 20-302 # ! 20-353 #
10-175 ! 20-107 # ! 20-158 # ! 20-303 # ! 20-354 #
10-176 ! 20-108 # ! 20-159 # ! 20-304 # ! 20-355 #
10-177 ! 20-109 # ! 20-160 # ! 20-305 # ! 20-356 #
10-178 ! 20-110 # ! 20-161 # ! 20-306 # ! 20-357 #
10-179 ! 20-111 # ! 20-162 # ! 20-307 # ! 20-358 #
10-180 ! 20-112 # ! 20-163 # ! 20-308 # ! 20-359 #
10-181 ! 20-113 # ! 20-164 # ! 20-309 # ! 20-360 #
10-182 ! 20-114 # ! 20-165 # ! 20-310 # ! 20-361 #
10-183 ! 20-115 # ! 20-166 # ! 20-311 # ! 20-401 #
10-184 ! 20-116 # ! 20-167 # ! 20-312 # ! 20-402 #
10-185 ! 20-117 # ! 20-168 # ! 20-313 # ! 20-404 #
10-186 ! 20-118 # ! 20-169 # ! 20-314 # ! 20-405 #
10-187 ! 20-119 # ! 20-170 # ! 20-315 # ! 20-406 #
10-188 ! 20-120 # ! 20-171 # ! 20-316 # ! 20-407 #
10-189 ! 20-121 # ! 20-172 # ! 20-317 # ! 20-408 #
10-190 ! 20-122 # ! 20-173 # ! 20-318 # ! 20-409 #
10-191 ! 20-123 # ! 20-174 # ! 20-319 # ! 20-410 #
10-192 ! 20-124 # ! 20-175 # ! 20-320 # ! 20-411 #
10-193 ! 20-125 # ! 20-176 # ! 20-321 # ! 20-412 #
10-194 ! 20-126 # ! 20-177 # ! 20-322 # ! 20-413 #
10-195 ! 20-127 # ! 20-178 # ! 20-323 # ! 20-414 #
10-196 ! 20-128 # ! 20-179 # ! 20-324 # ! 20-415 #
10-197 ! 20-129 # ! 20-180 # ! 20-325 # ! 20-416 #
10-198 ! 20-130 # ! 20-181 # ! 20-326 # ! 20-417 #
10-199 ! 20-131 # ! 20-182 # ! 20-327 # ! 20-418 #
10-200 ! 20-132 # ! 20-183 # ! 20-328 # ! 20-419 #
10-201 ! 20-133 # ! 20-184 # ! 20-329 # ! 20-420 #
10-202 ! 20-134 # ! 20-185 # ! 20-330 # ! 20-421 #
10-203 ! 20-135 # ! 20-186 # ! 20-331 # ! 20-422 #
10-204 ! 20-136 # ! 20-187 # ! 20-332 # ! 20-423 #
10-205 ! 20-137 # ! 20-188 # ! 20-333 # ! 20-424 #
10-206 ! 20-138 # ! 20-189 # ! 20-334 # ! 20-425 #
10-207 ! 20-139 # ! 20-190 # ! 20-335 # ! 20-426 #
10-208 ! 20-140 # ! 20-191 # ! 20-336 # ! 20-427 #
10-209 ! 20-141 # ! 20-192 # ! 20-337 # ! 20-428 #
10-210 ! 20-142 # ! 20-193 # ! 20-338 # ! 20-429 #
10-211 ! 20-143 # ! 20-194 # ! 20-339 # ! 20-430 #
! 20-144 # ! 20-195 # ! 20-340 # ! 20-431 #
! 20-1 # ! 20-145 # ! 20-196 # ! 20-341 # ! 20-432 #
! 20-2 # ! 20-146 # ! 20-197 # ! 20-342 # ! 20-433 #
! 20-3 # ! 20-147 # ! 20-198 # ! 20-343 # ! 20-434 #
! 20-4 # ! 20-148 # ! 20-199 # ! 20-344 # ! 20-435 #
! 20-5 # ! 20-149 # ! 20-200 # ! 20-345 # ! 20-436 #
! 20-6 # ! 20-150 # ! 20-201 # ! 20-346 # ! 20-437 #
! 20-7 # ! 20-151 # ! 20-202 # ! 20-347 # ! 20-438 #
! 20-101 # ! 20-152 # ! 20-203 # ! 20-348 # ! 20-439 #
! 20-102 # ! 20-153 # ! 20-205 # ! 20-349 # ! 20-440 #
! 20-103 # ! 20-154 # ! 20-206 # ! 20-350 # ! 20-441 #
! 20-104 # ! 20-155 # ! 20-207 # ! 20-351 # ! 20-442 #
00-2-2 HD465-7, HD605-7

➀
! 20-443 # ! 20-528 # ! 20-579 # ! 20-719 # ! 20-770 #
! 20-444 # ! 20-529 # ! 20-580 # ! 20-720 # ! 20-771 #
! 20-445 # ! 20-530 # ! 20-581 # ! 20-721 # ! 20-772 #
! 20-446 # ! 20-531 # ! 20-582 # ! 20-722 # ! 20-773 #
! 20-447 # ! 20-532 # ! 20-583 # ! 20-723 # ! 20-774 #
! 20-448 # ! 20-533 # ! 20-584 # ! 20-724 # ! 20-801 #
! 20-449 # ! 20-534 # ! 20-585 # ! 20-725 # ! 20-802 #
! 20-450 # ! 20-535 # ! 20-586 # ! 20-726 # ! 20-803 #
! 20-451 # ! 20-536 # ! 20-587 # ! 20-727 # ! 20-804 #
! 20-452 # ! 20-537 # ! 20-588 # ! 20-728 # ! 20-805 #
! 20-453 # ! 20-538 # ! 20-589 # ! 20-729 # ! 20-806 #
! 20-454 # ! 20-539 # ! 20-590 # ! 20-730 # ! 20-807 #
! 20-455 # ! 20-540 # ! 20-591 # ! 20-731 # ! 20-808 #
! 20-456 # ! 20-541 # ! 20-592 # ! 20-732 # ! 20-809 #
! 20-457 # ! 20-542 # ! 20-593 # ! 20-733 # ! 20-810 #
! 20-458 # ! 20-543 # ! 20-594 # ! 20-734 # ! 20-811 #
! 20-459 # ! 20-544 # ! 20-595 # ! 20-735 # ! 20-812 #
! 20-460 # ! 20-545 # ! 20-596 # ! 20-736 # ! 20-813 #
! 20-461 # ! 20-546 # ! 20-597 # ! 20-737 # ! 20-814 #
! 20-462 # ! 20-547 # ! 20-598 # ! 20-738 # ! 20-815 #
! 20-463 # ! 20-548 # ! 20-599 # ! 20-739 # ! 20-816 #
! 20-464 # ! 20-549 # ! 20-600 # ! 20-740 # ! 20-817 #
! 20-465 # ! 20-550 # ! 20-601 # ! 20-741 # ! 20-818 #
! 20-466 # ! 20-551 # ! 20-602 # ! 20-742 # ! 20-819 #
! 20-501 # ! 20-552 # ! 20-603 # ! 20-743 # ! 20-820 #
! 20-502 # ! 20-553 # ! 20-604 # ! 20-744 # ! 20-821 #
! 20-503 # ! 20-554 # ! 20-605 # ! 20-745 # ! 20-822 #
! 20-504 # ! 20-555 # ! 20-606 # ! 20-746 # ! 20-823 #
! 20-505 # ! 20-556 # ! 20-607 # ! 20-747 # ! 20-824 #
! 20-506 # ! 20-557 # ! 20-608 # ! 20-748 # ! 20-825 #
! 20-507 # ! 20-558 # ! 20-609 # ! 20-749 # ! 20-826 #
! 20-508 # ! 20-559 # ! 20-610 # ! 20-750 # ! 20-827 #
! 20-509 # ! 20-560 # ! 20-611 # ! 20-751 # ! 20-828 #
! 20-510 # ! 20-561 # ! 20-612 # ! 20-752 # ! 20-829 #
! 20-511 # ! 20-562 # ! 20-701 # ! 20-753 # ! 20-830 #
! 20-512 # ! 20-563 # ! 20-702 # ! 20-754 # ! 20-831 #
! 20-513 # ! 20-564 # ! 20-704 # ! 20-755 # ! 20-832 #
! 20-514 # ! 20-565 # ! 20-705 # ! 20-756 # ! 20-833 #
! 20-515 # ! 20-566 # ! 20-706 # ! 20-757 # ! 20-834 #
! 20-516 # ! 20-567 # ! 20-707 # ! 20-758 # ! 20-835 #
! 20-517 # ! 20-568 # ! 20-708 # ! 20-759 # ! 20-836 #
! 20-518 # ! 20-569 # ! 20-709 # ! 20-760 # ! 20-837 #
! 20-519 # ! 20-570 # ! 20-710 # ! 20-761 # ! 20-838 #
! 20-520 # ! 20-571 # ! 20-711 # ! 20-762 # ! 20-839 #
! 20-521 # ! 20-572 # ! 20-712 # ! 20-763 # ! 20-840 #
! 20-522 # ! 20-573 # ! 20-713 # ! 20-764 # ! 20-841 #
! 20-523 # ! 20-574 # ! 20-714 # ! 20-765 # ! 20-842 #
! 20-524 # ! 20-575 # ! 20-715 # ! 20-766 # ! 20-843 #
! 20-525 # ! 20-576 # ! 20-716 # ! 20-767 # ! 20-844 #
! 20-526 # ! 20-577 # ! 20-717 # ! 20-768 # ! 20-901 #
! 20-527 # ! 20-578 # ! 20-718 # ! 20-769 # ! 20-902 #
HD465-7, HD605-7 00-2-3

➀
! 20-904 # ! 20-955 #
! 20-905 # ! 20-956 #
! 20-906 # ! 20-957 #
! 20-907 # ! 20-1001 #
! 20-908 # ! 20-1002 #
! 20-909 # ! 20-1003 #
! 20-910 # ! 20-1004 #
! 20-911 # ! 20-1005 #
! 20-912 # ! 20-1006 #
! 20-913 # ! 20-1007 #
! 20-914 # ! 20-1008 #
! 20-915 # ! 20-1009 #
! 20-916 # ! 20-1010 #
! 20-917 # ! 20-1011 #
! 20-918 # ! 20-1012 #
! 20-919 # ! 20-1013 #
! 20-920 # ! 20-1014 #
! 20-921 # ! 20-1015 #
! 20-922 # ! 20-1016 #
! 20-923 # ! 20-1017 #
! 20-924 # ! 20-1018 #
! 20-925 # ! 20-1019 #
! 20-926 # ! 20-1020 #
! 20-927 #
! 20-928 # " 90-1 #
! 20-929 # 90-2
! 20-930 # 90-3
! 20-931 # 90-5
! 20-932 # 90-7
! 20-933 # 90-9
! 20-934 # 90-11
! 20-935 # 90-13
! 20-936 # 90-15
! 20-937 # 90-17
! 20-938 # ! 90-19 #
! 20-939 # ! 90-21 #
! 20-940 #
! 20-941 #
! 20-942 #
! 20-943 #
! 20-944 #
! 20-945 #
! 20-946 #
! 20-947 #
! 20-948 #
! 20-949 #
! 20-950 #
! 20-951 #
! 20-952 #
! 20-953 #
! 20-954 #
00-2-4 HD465-7, HD605-7

➀
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

• 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
Releasing pressure See Brake MPa See Brake

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

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

Operating force • When machine stopped (empty)
(Turning speed for steering N 14.7 – 29.4 Max. 35.3
(If it is impossible when the {kg} {1.5 – 3.0} {Max. 3.6}
wheel: 30 rpm) machine stopped, travel at low
speed with engine at low 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 → lock Turns 3.5 ± 0.3 3.5 ± 0.6
Left → right • Oil temperature: 60 – 80°C Max. 4 Max. 5

Turning • Engine speed: Whole range sec.
time • Lock → lock
Right → left 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)
N 234 ± 29.4 234 ± 29.4
Operating force (Full) {kg} {23.8 ± 3} {23.8 ± 3}
Brake pedal
Travel (Start of depress- mm 40 ± 5 40 ± 10

ing → Full)
HD465-7, HD605-7 20-5

➀

• 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

• 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 idling
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 44.8 ± 1.9 44.8 ± 1.9
• Center of control → HOLD
Travel mm
lever knob HOLD 44.8 ± 1.9 44.8 ± 1.9
→ LOWER
• Oil temperature:
Dump valve
At high idling (2,270 rpm) 20.1 – 21.1 19.6 – 22.6

45 – 55°C {205 – 215} {200 – 230}
Relief pres-
sure
At low idling (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 idling (2,270 rpm)
{35 ± 5} {35 ± 5}
Relief pres-
sure ( root
pressure)
At low idling (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 ± 1.5
Body
• Oil temperature: 45 – 55°C

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

➀
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 ................................................................................................................20-112
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
Inspecting return of fuel visually...................................................................................................................20-114
Testing and adjusting injector lift ..................................................................................................................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
Special functions of machine monitor (EMMS) ........................................................................................... 20-161
Pm-clinic service ......................................................................................................................................... 20-205
HD465-7, HD605-7 20-101

➀
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED 4. Measuring torque converter stall speed

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

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

➀
TESTING AND ADJUSTING 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 idling.
★ 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.
★ Measure the stall speed 2 or 3 times.
★ 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

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

machine monitor to the display of "Monitoring
SENSOR function of service mode 1", and check that the
engine speed is displayed normally.
★ If the engine speed sensor has been removed ★ 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).
★ 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.
★ Angle to return: 1/2 – 3/4 turns
★ Adjust clearance a between the tip of the
sensor and the tip of the gear tooth so that it
is 0.75 – 1.25 mm.
4. Secure sensor (1) in position with nut (3).

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

➀
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
C 790-261-1203 Digital type hydraulic tester

2 Hydraulic tester
799-401-2320
(1.0MPa {10kg/cm2})
★ 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)

★ 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)
★ The engine oil pressure is displayed in units of 1
kPa.
★ For the method of measurement, see MEASUR-
ING WITH MEASURING INSTRUMENTS.
3. Start the engine, and measure the oil pressure at

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

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

➀
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.
★ Measure the air supply pressure (boost pres-
sure) under the following conditions.
• Coolant temperature: Within operating range
• 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.
★ 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.
★ 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.
★ If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
★ For the method of measurement, see MEA-
used.
SURING WITH MEASURING INSTRU-
★ 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 idling to stall the torque

converter, and measure the air supply pressure
(boost pressure).
★ 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.
★ 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

➀
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
Special tool list
Digital tempera-
B 799-101-1502 –99.9 – 1,299°C
ture gauge
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.
★ Measure the exhaust temperature under the fol-
lowing conditions. 3. When measuring the exhaust temperature at
• Coolant temperature: Within operating range torque converter stall, do as follows.
• Torque converter oil temperature: Within oper- ★ To prevent the torque converter from over-
ating range heating, use the full stall (torque converter
• Hydraulic oil temperature: 45 – 55°C stall + hydraulic relief) to stabilize the
exhaust temperature, then stall only the
1. Remove exhaust temperature measurement torque converter and measure the tempera-
plug (1). ture.
1) Turn the power mode switch to the HIGH
POWER position.
the cooling water to the operating range.
3) Depress the parking brake pedal, turn the
parking brake switch TRAVEL, then set the
gearshift lever to the D position.
If the gearshift lever is operated to any
machine may move off even if the
brake is being depressed, so always
measure at the D position.
4) Depress the accelerator pedal gradually, run
the engine at high idling and stall the torque
2. Install sensor ➀, then connect to digital tempera- converter. At the same time, operate the
ture gauge B. dump lever to the LOWER position and
★ Clamp the wiring harness of the temperature relieve the oil pressure (full stall).
gauge at a suitable place to prevent it from ★ Continue until the exhaust temperature
touching any hot part. reaches the standard value of 670°C.
There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gearshift lever to any posi-
tion other than the D position during
the stall operation.
20-108 HD465-7, HD605-7

➀
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5) When the temperature stabilizes at near the

target temperature, return the dump lever to
FLOAT and measure the temperature with
only the torque converter stalled.
★ The exhaust temperature will start to go
down from the full stall condition, so
measure the temperature when it stabi-
lizes.
★ If the exhaust temperature does not go
down but rises, make the set tempera-
ture at full stall higher.
★ After completing the measurement, lower
the engine speed to low idling, then
return the gearshift lever to the N posi-
tion.
4. When measuring the maximum value for the

exhaust temperature during actual operation, do
as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
★ Use the PEAK mode of the digital tempera-
ture gauge. (Set the temperature gauge to
the PEAK mode. The maximum temperature
automatically recorded.)
★ The exhaust temperature largely depends on
the outside air temperature (intake air tem-
perature of the engine). Accordingly, if any
abnormal value is obtained, correct it by the
following calculation.
• Corrected value [°C] = Measured value +
2 x (20 – ambient temperature)

dition.
HD465-7, HD605-7 20-109

➀
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Special tool list
0 – 4.9 MPa
799-201-1504 Blow-by checker
{0 – 500 mmH2O}
1. Install nozzle and hose ➀ to blow-by hose (1),

then connect to blow-by checker E.

dition.
2. Start the engine and raise the temperature of the

cooling water to the operating range.
3. Depress the parking brake pedal, turn the park-

ing brake switch TRAVEL, then set the gearshift
lever to the D position.
If the gearshift lever is operated to any
machine may move off even if the brake is
being depressed, so always measure at
the D position.
4. Depress the accelerator pedal gradually, run the

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

➀
TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF 4. Compensate the measured value for each cylin-

der to judge which cylinder is defective.
INJECTOR ★ Compensation value
Unit:°C
Special tool list
Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Compen-
J 795-799-5510 Heat gun sation +20 +5 0 0 +5 +20
value
★ If the engine output drops or there is any other ★ Method of judgment
problem, if there is the possibility of defective Add up the temperatures after compensat-
combustion due to defective injection by the ing, then calculate the average temperature.
injector, carry out troubleshooting of injector. If the temperature of any cylinder is more
than 20°C lower than the average, judge that
1. Stop the engine and leave it to cool down. the cylinder is abnormal.
★ When cooling the engine down, as a guide- 1) Measurement and judgment example 1:
line, wait for the temperature of the exhaust Unit:°C
manifold to cool down to a temperature of
"ambient temperature +20°C".
Measured 85 62 79 112 89 82
value
2. Make marks for measurement to the exhaust
manifolds of the all cylinders. Compen-
sation 105 67 79 112 94 102
★ Make marks to the same points on the upper value
side or lower side of the exhaust manifolds of
Average
the all cylinders. value
93
3. Start the engine and run it at low idling for at No.2 cylinder is more than 20°C lower than
least 10 minutes. the average value, so judge that No.2 cylin-
★ Run it for at least 10 minutes to stabilize the der is abnormal.
exhaust temperature. 2) Measurement and judgment example 2:
Unit:°C
4. Using heat gun J, measure the temperature at Cylinder No.1 No.2 No.3 No.4 No.5 No.6
the outlet of the exhaust manifold of each cylin- Measured
der. 86 96 73 91 94 103
value
★ Measure the exhaust temperature at the top Compen-
or bottom of the exhaust manifold of each sation 106 101 73 91 99 123
cylinder. Measure at the same position for value
the all cylinders. Average 99
value
No.3 cylinder is more than 20°C lower than
the average value, so judge that No.3 cylin-
der is abnormal.
3) Measurement and judgment example 3:
Unit:°C
Measured 85 62 79 112 89 82
value
Compen-
sation 105 67 79 112 94 102
value
Average 93
value
No cylinder is more than 20°C lower than the
average value, so judge that all cylinders are
normal.
HD465-7, HD605-7 20-111

➀
MEASURING COMPRESSION PRESSURE
HANDLING EQUIPMENT IN FUEL SYSTEM
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
MEASURING COMPRESSION MEASURING FUEL PUMP

PRESSURE OUTLET PORT PRESSURE
★ For details of the method for measuring the Special tool list
blow-by pressure, see the 170-3 Series engine Symbol Part No. Part Name
shop manual.
799-101-5002 Hydraulic tester
C 1
790-261-1203 Digital hydraulic tester
1 795-799-5460 Cable
Commercially
K 2 Tester
available
3 795-799-5550 Adapter
HANDLING EQUIPMENT IN
FUEL SYSTEM 1. Measuring pressure sensor signal voltage
1) Disconnect connector CN-PMPR (1) of the
★ Precautions for inspection and maintenance of fuel pump pressure sensor, then connect
fuel system 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 prob-
lems may occur if dirt or dust get in.
When carrying out inspection and maintenance
of the fuel system, pay more attention than usual
to prevent dirt or dust from getting in. If there is
any dirt stuck to any part, use clean fuel to wash
it off completely.
★ Precautions when replacing fuel filter cartridge
Always use a genuine Komatsu part for the fuel
filter cartridge.
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so a spe-
2) Start the engine, switch the machine monitor
cial filter with high efficiency filtering ability is
to the display of "Monitoring function of ser-
used to prevent dirt or dust from getting in.
vice mode 1", and prepare to measure the
For this reason, if any filter is used as a substi-
engine speed.
tute for the genuine filter, there is danger that
★ For details of the method of operation, see
problems will occur with the fuel system. To pre-
SPECIAL FUNCTIONS OF MACHINE
vent this, never use such filters.
MONITOR (EMMS).
★ The engine speed is displayed in units of
1 rpm.
20-112 HD465-7, HD605-7

➀
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
3) Run the engine at low idling and check that

the source voltage of the fuel pump pressure
sensor is in the following range.
★ 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.
★ Signal voltage of sensor (Between –
):
Table 1 Engine speed and signal voltage
Engine Signal voltage Fuel pump outlet port
speed pressure (Reference)
1,000 rpm 1.68 ± 0.21 V 1.23 ± 0.14 MPa 3) Start the engine, switch the machine monitor
{12.6 ± 1.43 kg/cm2}
to the display of "Monitoring function of ser-
1,300 rpm 3.00 ± 0.21 V 1.57 ± 0.14 MPa vice mode 1", and prepare for measuring the
{16.0 ± 1.43 kg/cm2}
engine speed.
1,500 rpm 3.26 ± 0.21 V 1.78 ± 0.14 MPa ★ For details of the method of operation, see
{18.15 ± 1.43 kg/cm2}
SPECIAL FUNCTIONS OF MACHINE
MONITOR.
2. Measuring with pressure gauge (directly)
1) Fit adapter K3 to nipple (2) for measuring the
★ 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

➀
MEASURING FUEL PUMP INLET PORT PRESSURE (NEAGIVE PRESSURE)
TESTING AND ADJUSTING INSPECTING RETURN OF FUEL VISUALLY
MEASURING FUEL PUMP 3. Run the engine at a medium speed to bleed the
oil from the hose.
INLET PORT PRESSURE ★ Insert the connection of the negative pres-
(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 ★ If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
799-101-5002 Hydraulic tester
C 1 used.
790-261-1203 Digital hydraulic tester
★ If there is oil inside the hose, the gauge will
1 795-799-5550 Adapter not work, so always bleed the oil.
M Negative pressure gauge
2 795-799-5560 (0 – -0.1 MPa{0 – -1.02 kg/cm2})
4. Run the engine at full throttle and measure the
pump inlet port pressure (See Table 1).
1. Fit adapter M1 to pump inlet port pressure mea-
suring nipple (1). Table 1
2. Fit nipple ➀ of hydraulic tester C1 and hose ➁ to Fuel filter Fuel pump inlet port pressure
adapter M1 and connect them to negative pres- New Max. – 13.60 kPa {Max. – 102 mmHg}
sure gauge M2.
Used Max. – 27.10 kPa {Max. – 203 mmHg}
INSPECTING RETURN OF
FUEL VISUALLY
1. Disconnect fuel return hose (2) on the fuel tank
(1) side and inspect the returning condition of the
fuel visually.
20-114 HD465-7, HD605-7

➀
TESTING AND ADJUSTING TESTING AND ADJUSTING INJECTOR LIFT

INJECTOR LIFT
Special tool list
Commercially
F Dial gauge (Stroke: Min. 30 mm)
available
1. Open the engine hood cover.
2. Remove all cylinder head covers (1).
4. Set dial gauge F to the plunger head of the injec-

tor to be inspected.
★ Use a dial gauge with a stroke of at least 30
mm.
3. Rotate the crankshaft in the normal direction,

align [1.6TOP] line a on the damper with pointer
(2), and set the No.1 cylinder at compression top
dead center.
★ Use a barring device 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 5. Rotate the crankshaft, and measure the lift of the
hand and amount equal to the valve clear- plunger at the point where the deflection of the
ance. If the rocker arm does not move, it is dial gauge is the maximum.
not at compression top dead center, so • Max lift b: 20.00 mm
rotate the crankshaft one more turn.
★ The cylinder where the injector is inspected
is different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
• Cylinder at compression top dead center and
cylinder where injector is inspected.
Compression top 1 5 3 6 2 4
dead center
Injector to check 2 4 1 5 3 6
HD465-7, HD605-7 20-115

➀
TESTING AND ADJUSTING TESTING AND ADJUSTING INJECTOR LIFT
Adjusting 5. After completing the testing and adjusting, set to

★ If the lift is not corrrect, or if parts related to the the original condition.
injector have been removed and installed, adjust
Cylinder head cover mounting bolt:
as follows.
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
1. Follow Step 3 of the testing procedure and set
the cylinder for the injector to be adjusted to
compression top dead center.
★ The cylinder where the injector is inspected
is different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
• Cylinder at compression top dead center and
cylinder where injector is inspected.
Compression top 1 5 3 6 2 4
dead center
Injector to check 2 4 1 5 3 6
2. Completely loosen adjustment screw (3) of the

injector to be adjusted, then tighten with you fin-
gers.
★ Check that the bearing at the tip of the rocker
arm and the ball at the push rod end are fit-
ted securely in the injector and push rod
respectively.
3. Repeat the tightening and loosening operation

for adjustment screw (3), and finally tighten.
. Adjustment screw:
1st pass : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2nd pass: Loosen completely
3rd pass : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4th pass : Loosen completely
5th pass : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4. Hold adjustment screw (3) in position, then

tighten locknut (4).
Locknut: 205.8 – 245 Nm {21 – 25 kgm}
★ After tightening the locknut, repeat the test-
ing procedure to check the lift again.
20-116 HD465-7, HD605-7

➀
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.
Symbol Part No. Part Name Remarks 2) Connect the air hose and the socket of the
Handy smoke Discoloration 0 – 70% probe hose and accelerator switch to smoke
1 799-201-9000
checker (with standard color) meter G2.
G
(Discoloration x 1/10
2 795-502-1350 Smoke meter Bosch 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 E 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.
Commercially 5. Hold adjustment screw (5) in position, then
E Feeler gauge
available tighten locknut (6).
Locknut:
1. Open the engine hood.
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
★ After tightening the locknut, check the valve
2. Remove all cylinder head covers (1).
clearance again.
3. Rotate the crankshaft in the normal direction, to

6. Rotate the crankshaft 120° each time in the nor-
set the No.1 cylinder at compression top dead
center, and align [1.6TOP] line a on the damper mal direction and repeat the procedure in Steps
with pointer (2). 3 – 5 to adjust the valve clearance of each cylin-
★ Use a barring device on the flywheel housing der according to the firing order.
to carry out cranking. • Firiing order: 1–5–3–6–2–4
★ 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

➀
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 ★ Table of oil pressure measurement port posi-

Symbol Part No. Part Name Remarks tions and gauges to use
Pressure gauge Gauge
Analog hydraulic 2.5, 5.9, 39.2, No. Measurement location (MPa{kg/cm2})
799-101-5002 meter 58.8 MPa {25, 60,
C1 400, 600 kg/cm2} 1 Main relief pressure 5.9{60}
Pressure gauge 2 Torque converter inlet port pressure 2.45{25}
Digital hydraulic 58.8 MPa
799-401-2321 meter
{600 kg/cm2} 3 Torque converter outlet port pressure 2.45{25}
4 Torque converter lock-up clutch pressure 5.9{60}
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission 4th clutch pressure 5.9{60}
11 Transmission R clutch pressure 5.9{60}
5A-
11A Each clutch pilot pressure 5.9{60}
★ 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.
★ 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 idling.
4) After finishing measurement, remove the
measur ing instruments and retur n the
removed parts.
3) Start the engine and set the gear shift lever

in the "N", and then measure the oil pressure
at low idling and high idling.
measuring instruments and r eturn the
removed parts.
20-124 HD465-7, HD605-7

➀
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 idling, 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 idling.
measuring instruments 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

➀
Transmission related 5. Measuring transmission Lo clutch and pilot

★ 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
★ The mark indicates the speed ranges that are

actuated for each position of the gearshift lever.
★ The mark and mark indicate the clutches
that are actuated for each travel speed.
★ 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 idling.
approx. 11.5 km/h is reached, so check
carefully that the surrounding area is
safe.

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

➀
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 idling, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idling.
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

➀
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 idling, and 7) Release the brake, travel at high idling, 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

➀
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 idling, and 7) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idling.
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

➀
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
★ 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).
★ 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.
★ 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 idling.

• 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
install oil pressure gauge C1 (Oil pressure
Digital hydraulic Pressure gauge
790-261-1203
meter
58.8 MPa gauge: 39.2 MPa {400 kg/cm2}).
{600 kg/cm2}
J 566-35-43561 Nipple 18 × 1.5

(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.
★ 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 idling.i)
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
★ 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

➀
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.
★ After finishing measurement, bleed air, ★ 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.
★ 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
★ 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).
to escape slowly.
Air supply valve:
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
3. Adjusting of oil level

★ 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).
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.
Oil level valve:
39.2 – 49.0 Nm {4 – 5 kgm}
20-138 HD465-7, HD605-7

➀
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 When loosening the oil level valve,

INVERTED TYPE REAR gradually loosen only valve (1)
itself, and do not remove the valve
SUSPENSION CYLINDER until all the nitrogen gas has been
released from the slit.
★ Stop the machine empty on flat ground.
If the nitrogen gas has not all been
1. Testing length of cylinder
Check that dimension "a" of the rear suspension released, pressure sensor (5) are
cylinder is within the specified value. still under high pressure, so do not
loosen them under any circum-
Specified value for dimension "a" : 220 ± 10 mm
stances.
★ 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 ➁ between the stopper and
axle housing.
Thickness of block: 19 mm
Dimension a : 140 ± 3 mm
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 damage the valve core, so
remove the gas at the oil level valve.
★ When loosening the oil level valve,
loosen only the valve itself. Do not
loosen the pressure sensor or nipple.
HD465-7, HD605-7 20-141

➀
3. Adjusting oil level 4) Turn handle H11a of regulator H11 slowly

★ Release the nitrogen gas before adjusting clockwise, set the pressure reading of gauge
the oil level. H13 to 0.981 MPa {10kg/cm 2 } above the
1) Remove supply valve (3), and install joint internal pressure of the cylinder, then oper-
H6. ate valves H7 and H10 to fill the cylinder with
2) Install fitting H5 to joint H4, then connect nitrogen gas.
hose H3 and volume pump H2. ★ Fill the left and right cylinders in the
3) Loosen air bleed valve (1), then operate vol- same way.
ume pump H2 until no more bubbles come 5) When dimension "a" of the left and right cyl-
out with the oil from air bleed valve (1). inders reaches the standard value, turn han-
4) When no more bubbles come out with the dle H11a of regulator H11 counterclockwise
oil, tighten air bleed valve (1). to stop the flow of nitrogen gas.
5) After adding oil, remove the volume pump, ★ Standard dimension a : 220 ± 10 mm
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.
★ 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.
★ 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).
★ 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}).
20-142 HD465-7, HD605-7

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

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

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

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

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

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

➀
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

➀
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

➀
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.
★ 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 idling for 5 min-

utes.
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

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

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

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

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

CREASE voltage
POSITIONER SENSOR 4) Install mounting bolt (2).
5) Tighten locknut (1).
★ If the body positioner rod has been disconnected 6) Repeat the checking procedure above to
and connected again or the body positioner sen- check that the input voltage is within the nor-
sor has been removed and installed again, mal range.
inspect and adjust the body positioner sensor as
follows.
1. Checking sensor input voltage

1) Switch the machine monitor display to the
monitoring function of service mode 1 and
display the body positioner sensor input volt-
age.
★ Monitoring item
Code No. 34400: BODY POSITION
★ For details of the method of operation,
see SPECIAL FUNCTIONS OF MA-
CHINE MONITOR.
3. Calibrating system
Stop the machine on a level place and set

★ 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.
★ Check that the FLOAT caution lamp is
turned off.
3) With the body raised to the cylinder stopper,
2) Start the engine. run the engine at low idling and keep the
3) Operate the dump lever and check the moni- dump control lever in the RAISE position for
toring voltage when the dump lever is operat least 5 seconds.
ated fully to the LOWER position and RAISE 4) Run the engine at high idling and raise the
position. body to the stroke end. Then, lower the
★ When operated fully to LOWER: engine speed to low idling and set the dump
0.30 – 0.468 V control lever in the FLOAT position to lower
★ When operated fully to RAISE: the body to the seating position.
3.80 – 4.70 V ★ Repeat the operations of 3) and 4) above
5 – 10 times.
2. Adjusting link length 5) Run the engine at high idling and raise the
★ If the monitoring voltage is not within the nor- body to the stroke end. Then, keep the
mal range, adjust the length of the link as fol- engine speed at high idling and set the dump
lows. control lever in the LOWER position to lower
1) Loosen locknut (1). the body to the seating position.
2) Remove mounting bolt (2). ★ Repeat this operation 5 – 10 times.
3) Turn rod end (3) to adjust the length of
the link (4).
★ Standard installing length a: 433 mm.
★ Do not set installing length a less
than 430 mm.
★ Adjust the input voltage as follows.
• INCREASE link length to DE-
CREASE voltage
HD465-7, HD605-7 20-151

➀
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
★ Decide the escape method according to the following flowchart.
★ 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?
e C441KK (ENG) e BT2 --- No.3 start, tow machine to safe
R01 (engine start relay)
e 442KK (ENG) e BT2 --- No.15 place (see note)
e 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
e C111KT gine controller is replaced?
safe place (see note)
e 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
e C115KZ (ENG) Master speed sensor (SP1) not start, tow machine to
e 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

➀
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
Only in area where MPH is used
OFF Unit of speed meter: km/h Unnecessary
1 as unit
ON Unit of speed meter: MPH Unnecessary
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

➀
★ 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
★ 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

➀
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER
DJUSTING TRANSMISSION 3. Adjusting transmission

★ After carrying out any of the following opera-
CONTROLLER tions, adjust the transmission in order to
adjust the fitting between the transmission
1. Setting rotary switch and the transmission controller.
★ If the transmission controller has been • When the transmission has been over-
replaced, set the rotary switches for the net- hauled or replaced
work data and model selection as follows. • When the transmission control valve has
★ Use a precision cross-head screwdriver and been repaired or replaced
turn the rotary switch slowly. • When the transmission controller has
★ The ▲ mark on the rotary switch is the been replaced
guideline for setting. • When the power train speed sensor has
1) Remove 2 grommets at the top of the con- been repaired or replaced
troller. • When the transmission oil temperature
2) Align the SW1 rotary switch and SW2 rotary sensor has been repaired or replaced
switch with the set position. • When the transmission oil filter has
★ Rotary switches and set position. become clogged and has been cleaned
★ When adjusting the transmission, use the
Switch Purpose of switch Position service function of the machine monitor.
SW1 Model data 4
SPECIAL FUNCTIONS OF MACHINE MON-
SW2 Network data F
ITOR.
2. Setting machine body wiring harness

★ If the transmission controller is replaced, set
the connector for selecting the model as
shown below.
HD465, 605-7
MS11 – MS12 Connected
MS21 – MS22 Open
MS31 – MS32 Connected
20-160 HD465-7, HD605-7

➀
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)

• EMMS: Equipment Management Monitoring System
Normal functions and the special functions of machine monitor (EMMS)

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

Service meter, odometer display Electrical system trouble data dis- 14 Service meter setting function
1 8
function (default) play function 15 Odometer setting function
Distance traveled in reverse dis- Mechanical system trouble data
2 9 Distance traveled in reverse set-
play function display function 16
ting function
Filter, oil replacement interval 10 Machine data monitoring function
3
display function
11 Adjustment function
Telephone number input func-
4 Filter, oil replacement time setting
tion 12
function
5 Language selection function
Initialize function (exclusive func-
6 Action code display function 13
tion for factory)
7 Failure code display function
HD465-7, HD605-7 20-161

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

➀
HD465-7, HD605-7 20-163

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

➀
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)
★ 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)
★ The replacement time can be set using Ser-
vice mode 1.
HD465-7, HD605-7 20-165

➀
4. Telephone number input function

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

The language used for the machine monitor dis-
play can be selected by operating the switches
(Fig. 6)
★ The functions of Service mode 1 and Service
mode 2 are not included in the functions for
display selection, so they are always dis-
played in English.
6. Action code display function

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

While the action code is being displayed on the
machine monitor, press the [>] button once to dis-
play the failure codes for the existing failures (Fig.
8: example).
• [>] Button: Displays failure code
★ The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are recorded
as trouble data. (For details, see Service
mode 1.)
★ If more than one failure is occurring, press
the [>] button once more to display the other
failure codes.
★ After pressing the [>] button to display all the
existing failures, press the [>] button once
more to return to the service meter/odometer
display screen.
If the [>] button is pressed once more, the
failure codes will be displayed again from the
beginning.
If the switch is not operated for 10 seconds,
the display will switch automatically to the ac-
tion code screen.
★ With the service code display function, the
following data are displayed (Fig. 9).
A: Failure code
(4 digits for location code + 2 digits for
problem code)
B: Controller code
(MON: Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
(BK: Retarder controller)
C: System with problem
★ For details of the displayed failure codes, see
FAILURE CODE TABLE.
★ With the failure code display function and
trouble data display function (Service mode
1), the data that are displayed are partially
different.
★ If no switch is operated on the failure code
display screen for more than 30 seconds, the
display automatically returns to the action
code display screen.
HD465-7, HD605-7 20-167

➀
FAILURE CODES LIST

Failure Failure phenomenon Action
Failed section Controller
code (Phenomenon/Contents of failure) code
1380MW Lockup clutch Slip (MW) TW E03
1500LO Detection of double engagement See separate list (L0) TM E03
15B0NX Clogging of steering oil filter Clogging (NX) TM E01
15E0KM R → F gear shifting abuse 1 Mistake in operation or setting (KM) TM 
15E7KM R → F gear shifting abuse 2 Mistake in operation or setting (KM) TM 
15G0MW R clutch Slip (MW) TM E03
15H0MW Hi clutch Slip (MW) TM E03
15J0MW Lo clutch Slip (MW) TM E03
15K0MW 1st clutch Slip (MW) TM E03
15L0MW 2nd clutch Slip (MW) TM E03
15M0MW 3rd clutch Slip (MW) TM E03
15N0MW 4th clutch Slip (MW) TM E03
15SBL1 R clutch ECMV See separate list (L1) TM E03
15SBMA R clutch ECMV Malfunction (MA) TM E03
15SCL1 Hi clutch ECMV See separate list (L1) TM E03
15SCMA Hi clutch ECMV Malfunction (MA) TM E03
15SDL1 Lo clutch ECMV See separate list (L1) TM E03
15SDMA Lo clutch ECMV Malfunction (MA) TM E03
15SEL1 1st clutch ECMV See separate list (L1) TM E03
15SEMA 1st clutch ECMV Malfunction (MA) TM E03
15SFL1 2nd clutch ECMV See separate list (L1) TM E03
15SFMA 2nd clutch ECMV Malfunction (MA) TM E03
15SGL1 3rd clutch ECMV See separate list (L1) TM E03
15SGMA 3rd clutch ECMV Malfunction (MA) TM E03
15SHL1 4th clutch ECMV See separate list (L1) TM E03
15SHMA 4th clutch ECMV Malfunction (MA) TM E03
15SJL1 Lockup clutch ECMV 15SJ (L1) TM E03
15SJMA Lockup clutch ECMV 15SJ (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
AA10NX Air cleaner element Clogging (NX) TM E01
20-168 HD465-7, HD605-7

➀

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
C265KX Abnormality in fuel temperature sensor Disconnection or short circuit (KZ) ENG E01
HD465-7, HD605-7 20-169

➀

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
C551L4 Abnormality in idling validation switch circuit See separate list (L4) ENG E01
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

➀

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)
DDD7KX Failure in travel speed setting switch system (OP) Out of input signal range (KX) BK E03
DDD8KA Disconnection ARSO system switch (OP) Disconnection (KA) BK E03
DDD8KB Short circuit ARSO system switch (OP) Disconnection (KA) BK E03
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 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 Failure in suspension pressure sensor (FL) system Out of input signal range (KX) BK E03
(OPT)
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
HD465-7, HD605-7 20-171

➀

Dk11KX Failure in acceleration sensor system (OPT) 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
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
DLT3KA Transmission output shaft speed sensor Disconnection (KA) TM E03
dLt3KA Disconnection in transmission output shaft speed Disconnection (KA) BK E01

sensor
DLT3LC Transmission output shaft speed sensor See separate list (LC) TM E03
dLT3KA Disconnection in transmission output shaft speed Disconnection (KA) BK E01

sensor
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
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
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)
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)
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
20-172 HD465-7, HD605-7

➀

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
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
HD465-7, HD605-7 20-173

➀
★ 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)
20-174 HD465-7, HD605-7

➀
Procedure for switching to Service mode 1 and

screen display
★ When using Service mode 1, 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
★ 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).
★ 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.
★ 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 1 is displayed (Fig.
3).
★ Once the ID has been input and confirmed, it
remains effective until the starting switch is
turned OFF.
HD465-7, HD605-7 20-175

➀
5) Menu selection in Service mode 1

Press the [>] or [<] buttons on the menu screen
and the menus of Service mode 1 are displayed
endlessly in the following order (Fig. 4).
★ 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.
★ Note that if the [■] button is pressed on
the YES/NO screen, the function will be
executed.
★ 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

➀
8. Electrical system trouble data display func-

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

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

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

➀
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
★ 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).
★ The data for an existing problem (flashing
display) cannot be deleted.
20-178 HD465-7, HD605-7

➀
9. Mechanical system trouble data display func-

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

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

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

➀
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)

★ The trouble data for the mechanical sys-
tem cannot be deleted.
20-180 HD465-7, HD605-7

➀
10. Machine data monitoring function (REAL-

TIME MONITOR)
The machine monitor can monitor the condition
of the machine in real time through the signals
from the sensors installed to various parts of the
machine.
In the machine data monitoring function, the fol-
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
on the menu screen of Service mode 1 (Fig.
1).
2) Display sub menu

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

If the [>] button or [<] button is pressed on the
sub menu screen, the sub menu displays
endlessly in the following order (Fig. 3).
★ The sub menu is displayed in the [ ] por-
tion.
• [<] button: Goes 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

➀
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
★ Scroll the monitoring items to display in
the internally set order.
★ If the button is kept pressed, the items
will scroll at high speed.
★ 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)
★ 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
21 Clogging status of brake cooling filter CLOGGED/NOR- Status display

RETARD FILTER 35700 MAL
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 froke 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

➀
BRAKE [Retarder controller system]

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

SPEED
44 Wheel speed (RL) WHEEL SPEED 39700 0.0 – 65535 pm
RL
45 Wheel speed (RR) WHEEL SPEED 39701 0.0 – 65535 rpm
RR [0000 – FFFF]
XXXXRYYY
part No. from left
are displayed]
46 Part No. of software (For main CPU) BRAKE ROM 1 20206 Example: If part Status display
No. is 7831-46-
R110, 3146R110 is
displayed.
XXXXRYYY
part No. from left
are displayed]
47 Part No. of software (For sub-CPU) BRAKE ROM 2 35400 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

➀
11. Adjustment function (TUNING)

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

chine monitor and machine itself, and carry out
the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjust-
ment operation.
(1) Adjusting individual difference of valve (02:
ECMV TUNING AUTO)
(2) Resetting gearshifting feeling stabilized
learning data (01: TM TRIGGER)
(3) Gearshifting feeling stabilized initial learning
(monitoring function)
★ The MANUAL menu of [02: ECMV TUNING]
is a special function for the factory and is not
used for service.
HD465-7, HD605-7 20-191

➀
Preparatory work:
Adjusting ECMV oil temperature
★ 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. 46
3) Raise ECMV oil temperature to 50 – 60°C by

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

Before carrying out adjustment, be sure to check
that ECMV oil temperature is kept within 50 –
60°C.
20-192 HD465-7, HD605-7

➀
Adjustment operation (1): Adjusting individual

difference of valve
★ See Preparatory work and check that the ECMV
oil temperature is at the specified temperature.
★ The adjustment operation is carried out automat-
ically three 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
★ The adjustment is carried out consecutively three
times for the applicable clutches and displays a
screen like the one shown on the right.
★ For each adjustment operation, the result is dis-
played as normal or abnormal, so take action ac-
cording to the display (Fig. 6).
• If [3-3 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
• If [NG 1] (Outside compensation condition) is dis- 1 Lo IP L-1 IP L-2 IP L-3
played:
2 Hi IP H-1 IP H-2 IP H-3
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
peat from Step 1). 4 1st IP 1-1 IP 1-2 IP 1-3
• If [NG 2] (No fill) is displayed: 5 2nd IP 2-1 IP 2-2 IP 2-3
Carry out troubleshooting for failure codes 6 3rd IP 3-1 IP 3-2 IP 3-3
[15S[ ]MA] [DDT[ ]KA], and if it is found to be 7 4th IP 4-1 IP 4-2 IP 4-3
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

➀
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
★ The present initial status is displayed on the
bottom line of the screen.
• Initializing completed: INITIAL STATUS
• Initializing not performed: TUNED
★ 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).
★ After carrying out initializing, check that INI-
TIAL STATUS is displayed on the bottom line
of the screen.
20-194 HD465-7, HD605-7

➀
Adjustment operation (3): Initial learning of gear-

shifting feeling stabilization
★ Check that the ECMV oil temperature is the spec-
ified temperature. For details, see Preparatory
work.
Carry out the adjustment operation in a place

with ample room for traveling and where the sur-
rounding area is safe.
1) With the machine data monitoring function, dis-
play (R clutch fill status] (Fig. 10).
• TRANSMISSION No. 36
2) Run the engine at low idling, hold the gearshift
lever at the N position for 10 seconds, then oper-
ate the gearshift lever as follows.
★ Gearshift lever operation: N > R > N
3) Check the fill status with the monitoring display.
★ If the display is [0], go on to the next step.
★ If the display is [1], repeat Step 2) until it be-
comes [0].
4) Operate the gearshift lever to the D position,
drive the machine, and shift up to F2 – F4.
★ Shift up: F2 > F3 > F4
★ Be careful not to shift up to F5. If the trans-
mission shifts up to F5, start the procedure
again and move the machine off in F2.
5) After traveling for 10 seconds in F4, release the
accelerator pedal, and allow the machine to
coast and shift down from F4 to F2.
★ Shift down: F4 > F3 > F2
★ Do not operate the brake while coasting.
6) Use the machine data monitoring function to dis-
play [Lo clutch fill status] and [1st clutch fill sta-
tus] and check the fill status (Fig. 11).
• Lo clutch: TRANSMISSION No. 35
• Hi clutch: TRANSMISSION No. 37
★ If the display is [0], the correction is com-
plete.
★ If the display is [1], repeat Steps 4) and 5) un-
til it becomes [0].
HD465-7, HD605-7 20-195

➀
12. Filter, oil replacement time setting function

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

item
i) With the menu selected, press the [ ]
button and display the initial screen of
the set item (Fig. 2).
ii) Press the [>] or [<] buttons to select the
item to be set.
• [>] button: Goes on to next item
• [<] button: Goes back to last item
★ 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

➀
i) Operate the buttons to input the interval

(Fig. 4).
down
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
13. 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

➀
Procedure of switching the service mode to the

service mode 2
★ When replace the machine monitor to the new
one, change the data shown below to the data of
the machine.
• Service meter data
• Odometer data
• Reverse travel odometer data
★ Never use this function except when replacing
the machine monitor to the new one.
★ Because it is necessary to operate the connetors
behind the machine monitor, when replacing the
machine monitor, carry out this procedure before
installing the cover.
★ In case of using service mode 2, switch the dis-
play by carrying out the procedure mentioned be-
low.
1) Switching the service mode to the service

mode 1.
Set the service mode to the service mode 1
by operating the machine monitor.
★ Switching the service mode to the ser-
vice mode 2 is possible only when the
service mode is on the service mode 1.
2) Operating the connectors and confirming the

display.
i) Connect the OP7 connectors behind the
machine monitor, and then disconnect
them. (Fig. 1)
★ After operating the OP7 connectors,
keep them disconnected.
ii) After operating the connectors, confirm
that the new initial display of service
mode 2 is displayed. (Fig. 2)
• Initial display: Service meter setting
function
HD465-7, HD605-7 20-199

➀
3) Menu selection
Press the [>] or [<] buttons on the opening
menu screen and the menus of Service
mode 2 are scrolled in the following order.
★ The menu is displayed in the places
marked with [*].
• [<] button: Goes back to previous menu
(1) Hourglass mark: Service meter setting
function
(2) ODO: Function for setting value for total
distance traveled
(3) BACKWARD ODO: Function for setting
value for total distance traveled in re-
verse
4) 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.
★ Note that if the [■] button is pressed
on the YES/NO screen, the function
will be executed.
★ If you return to the normal screen
(operator mode) or service mode by
mistake, repeat the procedure from
Step 1) above (there is no need to in-
put the ID again).
(2) When completing all operations:
Turn the starting switch OFF.
20-200 HD465-7, HD605-7

➀
14. Service meter setting function (hourglass

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

button and display the service meter
input screen (Fig. 2).
ii) Operate each button and input the ser-
vice meter times.
down
firmed
• [■] button: Returns to initial screen
(see Note)
★ The time must always be input with
five digits. For numbers of less than
five digits, input 0 at the beginning.
iii) When all the times are confirmed, the
change confirmation screen is dis-
played, so operate the buttons accord-
ing to the screen display (Fig. 3).
HD465-7, HD605-7 20-201

➀
15. Odometer setting function (ODO)

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

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

➀
16. Distance traveled in reverse setting function

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

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

➀
TESTING AND ADJUSTING PM-CLINIC SERVICE
Pm-CLINIC SERVICE Machine Serial No.

HD465-7
Engine Serial No.
HD605-7
HOUR INSPECTION
WORK No. DATE SERVICE METER NAME OF INSPECTOR

Year Month Day
hrs
QUESTIONS TO OPERATOR AND INSPECTION AROUND THE MACHINE

Was there any abnormality before start of inspection ? Ambient Temperature
Max. °C(°F)
Min. °C(°F)
Altitude m
Is maximum cooling water temperature level normal ? Is maximum torque converter oil temperature level normal ? Is maximum retarder oil temperature level normal ?
(During operation) (During operation) (During operation)
AFTER STARTING ENGINE !
MEASUREMENT ITEM MEASUREMENT CONDITION UNIT STD. PMS. RESULT Sat Us
Low idling, Low 700 -- 800 700 -- 800

Low idling, Hi 895 -- 995 895 -- 995
Power mode, high idling 2,220 -- 2,320 2,220 -- 2,320
Economy mode, high idling 2,150 -- 2,250 2,150 -- 2,250
Engine speed rpm
Stationary Parking brake switch in
PARKING + Shift lever in 2,000 -- 2,100 2,000 -- 2,100
mode N + Hoist lever in FLOAT
Power mode, torque converter stall 1,810 -- 2,010 1,810 -- 2,010
Economy mode torque converter stall 1,810 -- 2,010 1,810 -- 2,010
kPa Max. 5.4 Max. 8.8
Blow-by pressure Power mode, torque converter stall {mmAq}
{Max. 550} {Max.900}
ENGINE
Power mode, high 0.39 -- 0.54 Min. 0.21

SAE30 {4.0 -- 5.5} {Min. 2.1}
idling (2,270rpm)
Low idling, Low Min. 0.12 Min. 0.08
Engine lubricating (750rpm) Mpa {Min. 1.2} {Min. 0.8}
oil pressure Power mode, high {kg/cm2} 0.34 -- 0.54 Min. 0.18
SAE10W {3.5 -- 5.5} {Min. 1.8}
idling (2,270rpm)
Low idling, Low Min. 0.1 Min. 0.07
(750rpm) {Min. 1.0} {Min. 0.7}
kPa Min. 106.6 Min. 93.3
Boost pressure Power mode, torque converter stall {mmHg} {Min. 800} {Min. 700}
Ambient temperature
(at air cleaner suction port) ---- ----
Exhaust temperature Power mode, # 1, 2, 3 °C Max. 670 Max. 700
torque converter
stall # 4, 5, 6 Max. 670 Max. 700
( ) : Reference value
T/C oil temperature : 75 -- 85°C ---- ---- ----
0.74±0.05 0.74±0.05
T/C inlet oil pressure At engine speed 2,000rpm {7.5±0.5} {7.5±0.5}
At power mode, high idling (2,270rpm) 0.88±0.05 0.88±0.05
{8.9±0.5} {8.9±0.5}
At low idling, Low (750rpm) 0.17±0.05 0.17±0.05
T/C
Mpa {1.7±0.5} {1.7±0.5}

{kg/cm2} 0.59±0.05 0.59±0.05
T/C outlet oil At engine speed 2,000rpm
{6.0±0.5} {6.0±0.5}
pressure
At power mode, high idling (2,270rpm) 0.71±0.05 0.71±0.05
{7.2±0.5} {7.2±0.5}
At low idling, Low (750rpm) 0.15±0.05 0.15±0.05
{1.5±0.5} {1.5±0.5}
HD465-7, HD605-7 20-205

➀
T/C oil temperature : 75 -- 85°C ---- ---- ----

1.67±0.20 1.67±0.20
Look up oil pressure At engine speed 2,000rpm {17±2} {17±2}
1.67±0.20 1.67±0.20
At power mode, high idling (2,270rpm) {17±2} {17±2}
1.67±0.20 1.67±0.20
At low idling, Low (750rpm) {17±2} {17±2}
3.68±0.15 3.68±0.15
Main relief oil At engine speed 2,000rpm {37.5±1.5} {37.5±1.5}
T/C
pressure 3.77±0.15 3.77±0.15

Mpa
At power mode, high idling (2,270rpm) {kg/cm2} {38.5±1.5} {38.5±1.5}
3.33±0.15 3.33±0.15
At low idling, Low (750rpm) {34±1.5} {34±1.5}
0.15±0.05 0.15±0.05
T/M lubicating oil At engine speed 2,000rpm {1.5±0.5} {1.5±0.5}
pressure
0.17±0.05 0.17±0.05
At power mode, high idling (2,270rpm) {1.7±0.5} {1.7±0.5}
0.09±0.05 0.09±0.05
At low idling, Low (750rpm) {0.9±0.5} {0.9±0.5}
CHANGE OIL, CLEAN OF TRANSMISSION CASE AND STRAINER AT EVERY 1000 HOURS SERVICE !
T/M
Visual check of transmission strainer ---- Must be no excessive metallic particles or Rayflex (black powder)
Steering time lock to Low idling, Hi right left Max. 4.0 Max. 5.0
sec
STEERING
lock Low idling, Hi left right Max. 5.0

Max. 4.0
20.2 -- 21.1 20.1 -- 23.5
At power mode, high idling (2,270rpm) Mpa {206 -- 215} {205 -- 240}
Steering relief oil
pressure {kg/cm2} 20.2 -- 21.1 20.1 -- 23.5
At low idling, Low (750rpm) {206 -- 215} {205 -- 240}
17.6±1.2 17.6±1.2
Charge accumulator Front {180±12} {180±12}
and operate brake 1
Mpa 9.8±0.7 9.8±0.7
Brake oil pressure time and measure Rear {kg/cm2} {100±7} {100±7}
operating pressure at
8.7±0.6 8.7±0.6
this time
BRAKE
Retarder {88.5±6.5} {88.5±6.5}

Service brake Must not move at 1,870 rpm.
Apply brake, set gear shift lever to
Retarder brake D, gradually raise engine speed Must not move at 1,400 rpm.
rpm
Parking brake and measure engine speed when Must not move at 1,670 rpm.
machine starts to move
Emergency brake Must not until T/C stalls.
Hydraulic oil temperature : 45 -- 55 °C ---- ---- ----
HYDRAULIC EQUIPMENT
At power mode, high idling (2,270rpm) 20.1 -- 21.1 19.6 -- 22.6

{205 -- 215} {200 -- 230}
Hoist relief pressure
18.6 -- 19.6 18.6 -- 19.6
At low idling, Low (750rpm)
Mpa {190 -- 200} {190 -- 200}
{kg/cm2} 3.4±0.49 3.4±0.49
At power mode, high idling (2,270rpm)
Dump EPC valve root {35±5} {35±5}
pressure 2.6±0.49 2.6±0.49
At low idling, Low (750rpm) {27±5} {27±5}
Dump body raise time Engine at full in POWER mode 10.0 -- 13.0 10.0 -- 13.0
sec
Dump body lowering time Engine at low idling LOW, in FLOAT position 9.5 -- 12.5 9.5 -- 12.5
SET DUMP BODY AND STOP ENGINE !

Hydraulic oil temperature : 45 -- 55 °C ---- ---- ----
HYDRAULIC
DRIFT
Hydraulic drift of Set dump body with No. 2 cylinder

mm/5 min Max.85 Max.170
hoist cylinder extender 200 mm
20-206 HD465-7, HD605-7

➀
REPLACE DRAIN PLUG WITH SPARE PLUG !

Visual check of Stop engine ---- There must be no excessive metal

differential drain plug powder
AXLE
Visual check of final Left There must be no excessive metal

----
drive drain plug Right powder
SET DUMP BODY AND STOP ENGINE !

Front brake Left 19.5 3.0
mm
BRAKES
(pad thickness) Right 19.5 3.0

Rear brake Left Must be in wear gauge range
(disk wear measure-
ment gauge) Right Must be in wear gauge range
Left front Suspension cylinder length mm 239 -- 259 229 -- 269

suspension Oil, gas leakage ---- There must be no leakage
Right front Suspension cylinder length mm 239 -- 259 229 -- 269

suspension
SUSPENSION
Oil, gas leakage ---- There must be no leakage
Left rear Suspension cylinder length mm 210 -- 230 200 -- 240

Suspension cylinder length mm 210 -- 230 200 -- 240
Right rear
Contact of rear Left ---- There must be no contact

suspension stopper Right ---- There must be no contact
MEMO : Write any data or phenomena that you noticed during today's check.
HD465-7, HD605-7 20-207

➀
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 hydraulic and mechanical systems (H mode) ............................................................ 20-1001
HD465-7, HD605-7 20-301

➀
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

➀
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

➀
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
• 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

➀
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
Item Judgement
Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil, coolant
4. Check hydraulic strainer — Clean, drain

5. Check power train oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check power train oil filter — Replace
10. Check hydraulic filter — Replace
11. Check final drive oil level — Add oil
12. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
13. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
14. Check for looseness, corrosion of starting motor terminal, — Tighten or replace
wiring
15. Check operation of gauges — Repair or replace
Hydraulic, mechani-
16. Check for abnormal noise, smell — Repair

cal equipment
17. Check for oil leakage — Repair

18. Carry out air bleeding — Bleed air
19. Check battery voltage (engine stopped) 24 – 26 V Replace

Electrics, electrical equipment
20. Check battery electrolyte level — Add or replace

21. Check for discolored, burnt, exposed wiring — Replace
22. Check for missing wiring clamps, hanging wiring — Repair
23. Check for water leaking on wiring (pay particularly careful — Disconnect connec-
attention to water leaking on connectors or terminals) tor and dry
24. Check for blown, corroded fuses — Replace

25. Check alternator voltage (engine running at 1/2 throttle After running for
or above) several minutes: Replace
27.5 – 29.5 V
26. Check operating sound of battery relay (starting switch
ON, OFF) — —
20-312 HD465-7, HD605-7

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

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

➀
Phenomena considered to be failures and troubleshooting No.

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

Engine does not Engine turns but no exhaust smoke comes
4 S-2 b)
start out
5 Exhaust smoke comes out but engine S-2 c)
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 (or exhaust smoke is blue) S-8
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 level goes S-11
down
15 Oil pressure caution lamp lights up (drop in oil pressure) S-12
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
preheating Engine is still preheated after preheating ENG-2b)
time
When AISS switch is set in AUTO, LOW ENG-3a)
AISS function SPEED control is selected
21 does not work
normally When AISS switch is set in LOW SPEED, ENG-3b)
AUTO control is selected
22 Not error code is displayed in error code display mode TM-
1 – 27
Hydraulic and mechanical related
23 Machine does not start H-1
24 Machine does not travel smoothly (machine jerks) H-2
25 Lock-up clutch cannot be disengaged (engine stalls) H-3
26 Excessive shock when starting or shifting H-4
27 Transmission Does not shift up H-5

does not shift up
20-314 HD465-7, HD605-7

➀
Troubleshooting
Abnormality at all speed ranges H-6a)
Machine lacks
28 power or speed Torque converter lock-up does not engage H-6b)
when traveling
Abnormality at specific speed ranges H-6c)
29 Time lag is excessive when starting or shifting gear H-7
30 Torque converter oil temperature is high H-8
31 Torque converter oil pressure is low H-9
32 Front brake is ineffective, or effective only on one side H-10
33 Rear brake is ineffective, or effective only on one side H-11
34 Steering wheel is heavy H-12
35 Steering wheel does not work H-13
36 Steering wheel vibrates H-14
37 Hoist cylinder lacks lifting force (lifting speed) H-15
38 Hoist cylinder does not work H-16
39 Excessive hydraulic drift of dump body H-17
Transmission controller related
40 Fuel level gauge does not operate normally TM-1

(It always indicates "FULL")
When the shift lever is set in the "R"
41 position, the backup lamp and backup TM-2a)
buzzer are not turned ON
Abnormality in Backup lamp is not turned ON (Backup
42 backup lamp buzzer is normal) TM-2b)
and backup
43 buzzer Backup buzzer is not turned ON (Backup TM-2c)
lamp is normal)
44 While shift lever is not operated, backup TM-2d)
lamp and backup buzzer are turned ON
Retarder controller related
When the parking brake switch is set in the
OFF position, the parking brake s not BK-1a)
Parking brake released
45 does not
operate normally When the parking brake switch is set in the
PARK position, the parking brake does not BK-1b)
work
46 Retarder brake oil temperature gauge does not operate BK-2
normally
47 Inclination alarm is turned ON when dump body is raised BK-3
(when machine is not inclined more than 15°)
48 Touch up/down and cancellation cannot be performed BK-4
Payload meter related
49 When starting switch is turned ON, any item is not displayed LC-1
50 After starting switch is turned ON, all external pilot lamps do not LC-2
light up
51 External lamps light up while condition for lighting is not set LC-3
52 Lighting level of external pilot lamps is abnormal LC-4
53 Cycle data and engine ON/OFF data not recorded LC-5

(charge level signal system: judges that engine is stopped)
54 Calibration cannot be performed and displayed clock does not LC-6
conform to condition (shift lever "N" position signal system)
HD465-7, HD605-7 20-315

➀
Troubleshooting
55 When loaded dump truck st arts LC-7a)
traveling, "0" is kept displayed
After loaded dump truck start
56 traveling, display of odometer does LC-7b)
not increase
Displayed logic is
57 abnormal When travel speed exceeds limit LC-7c)
speed, "SP:SP" does not go off
58 Integrated pay load is not displayed LC-7d)
59 Displayed and saved pay load is not LC-7e)

correct
Payload meter keeps displaying "b:FL"
60 (body "FLOAT" signal system: dump lever is not in "FLOAT" LC-8
position while truck is not dumping)
61 Payload meter displays "F:09" LC-9
(lowering of internal backup battery voltage)
62 Payload meter displays " :FULL" (data saving memory is full) LC-10
63 Payload meter displays "F-20" :failure in power source of LC-11

suspension pressure sensor and clinometer system
64 Payload meter displays "F-21" – "F-24" : disconnection or LC-12
grounding fault in suspension sensor signal system
65 Payload meter displays "F-25" – "F-28" : short circuit with power LC-13
source in suspension sensor signal system
66 Payload meter displays "F-CAL" LC-14
(negligence of calibration or internal damage of payload meter)
67 Payload meter displays "F:43" – "F:45" LC-15
(short circuit with power source in external pilot lamp relay system)
68 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 being
69 loaded or clock is displayed while truck travels for 160 m after LC-17
it is loaded
70 Payload meter displays "F-31" : grounding fault or LC-18
disconnection in clinometer sensor signal system
71 Payload meter displays "F-32" : short circuit with power source LC-19
in clinometer sensor signal system
72 Payload meter displays "F:18" LC-20
(disconnection in charge level signal system)
Monitor related
73 When starting switch is turned ON, machine monitor does not MON-1
display any item
74 When starting switch is turned OFF and machine monitor does MON-2
not operate normally
Alarm buzzer does not sound MON-3a)
75 Alarm buzzer
defective
Alarm buzzer does not stop sounding MON-3b)
Items displayed by gauges are MON-4a)
Items displayed by different from machine condition
gauges, caution
76 lamps, and character Items displayed by caution lamps MON-4b)
display of machine are different from machine condition
monitor are abnormal Character display does not display MON-4c)
any item or it displays abnormally
77 Operation of machine monitor cannot be checked normally MON-5
Machine monitor mode select switch MON-6a)
Display of character 1 system is abnormal
78 display cannot be
selected normally Machine monitor mode select switch
2 system is abnormal MON-6b)
79 Power mode select function does not work normally MON-7

Lamp lights up while seat belt is MON-8a)
Seat belt caution lamp fastened
80 does not operate
normally Lamp does not light up while seat MON-8b)
belt is unfastened
20-316 HD465-7, HD605-7

➀
Troubleshooting
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 operated,
turn signal lamps on either or both
sides do not flash (When hazard MON-9c)
lamp switch is operated, however,
turn signal lamps flash normally)
Turn signals and
81 hazard lamp do not When hazard lamp switch is turned
operate normally ON, any turn signal lamp does not
flash (When turn signal lever is MON-9d)
operated, however, turn signal lamps
flash normally)
When hazard lamp switch is turned
OFF, turn signal lamps continue
flashing (When turn signal lever is MON-9e)
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, night MON-10a)
lamp, and head lamp does not light
up
When lamp switch is set in 1st
position, small lamp and night lamp MON-10b)
do not light up
When lamp switch is OFF, small
lamp and night lamp light up MON-10c)
When dimmer switch is operated,
brightness of night lighting does not MON-10d)
Night lighting is change
82 abnormal When lamp switch is set in 2nd
position, head lamp "Lo" does not MON-10e)
light up
Head lamp "Hi" beam does not light
up MON-10f)
Head lamp "Lo" beam does not light
up MON-10g)
Head lamp cannot be set to "Hi" or
"Lo" MON-10h)
When head lamp is set to "Hi" beam,
pilot lamp of machine monitor does MON-10j)
not light up
Operating left side does not MON-
Power window does 11a)
83 not operate normally
Operating right side does not MON-
11b)
HD465-7, HD605-7 20-317

➀
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
8 799-601-7390
Part No.: 08056-00871 Part No.: 08056-00881
HD465-7, HD605-7 20-321

➀
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

➀
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

➀
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

➀
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
AMPO70-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
HD465-7, HD605-7 20-327

➀
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
10 12G: 799-601-9130
12Br: 799-601-9140
HD465-7, HD605-7 20-339

➀
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

➀
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 ! !

799-601-9240 HD30 18-21 ! !
799-601-9250 HD24 24-9 ! !
799-601-9260 HD30 2-16 ! !
799-601-9270 HD30 24-21 ! !
799-601-9280 HD30 24-23 ! !
799-601-9290 HD30 24-31 ! !
799-601-9310 Plate For HD30 ! ! !
799-601-9320 For measuring box For DT, HD ! ! !
799-601-9330 Case !
799-601-9340 Case !
799-601-9350 DEUTSCH 40P !
799-601-9360 DEUTSCH 24P !
799-601-9410 For NE, G sensor 2P !
For boost pressure,
799-601-9420 fuel 3P !
799-601-9430 PVC socket 2P !
HD465-7, HD605-7 20-343

➀
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
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 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 1 Air conditioner wiring harness M3 C-7

connector
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
ACM3 AMP 5 Recirculated/Fresh air selection W3 A-7

servomotor
ACP1 AMP 16 Air conditioner control panel O7 B-9
20-344 HD465-7, HD605-7

➀
Address
Con- Type Num-
3-dimen-
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
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 W4 A-3

(Transmission controller)
B01 DT-T 6 Intermediate connector K9 M-5
B02 DT-T 6 Intermediate connector K8 M-5
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 1 Lamp (Optional for payload meter) — I-9

connector
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 1 Lamp (Optional for payload meter) — H-1
connector
HD465-7, HD605-7 20-345

➀
Address
Con- Type Num-
3-dimen-
One-pin
B3 connector 1 Lamp (Optional for payload meter) — J-9
One-pin
B3 connector 1 Lamp (Optional for payload meter) — H-1
One-pin
BCOM connector 1 Beacon lamp T9 A-2
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
BRC3A AMP040 20 Retarder controller Y4 C-1 A-6 D-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
BRC6 X 4 Software rewriting connector S9 A-2

(Retarder controller)
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
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 (Gray) 8 Intermediate connector Q9 F-1
CAB2 DT-T (Black) 8 Intermediate connector Q9 B-9
CAN DT 3 CAN connector AJ6 H-9 L-6 M-3
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 (Black) 8 Joint connector B7 I-1 M-9
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
20-346 HD465-7, HD605-7

➀
Address
CJE3 DT-T (Black) 8 Joint connector A12 G-1 M-1 L-3 K-1 N-7
CJH1 DT-T (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 (Black) 8 Joint connector L8 G-9 N-5
CJT1 DT-T (Black) 8 Joint connector L7 G-1
CJT2 DT-T 6 Joint connector H9 G-1
CK1 YAZAKI 6 Bulb breakage check switch M2 F-9
CLTP PACKARD 2 Cooling water temperature sensor AE8 A-1
CM DT-T (Green) 8 Lighting switch, passing switch, turn switch Q8 B-2
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
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 clutch Z8 M-7
CN21 DT-T 2 Fill switch for torque converter lockup Z8 N-7

clutch
HD465-7, HD605-7 20-347

➀
Address
Con- Type Num-
3-dimen-
CN22 DT-T 3 Torque converter intermediate pressure Z5 M-8

sensor
CN23 DT-T 2 Torque converter oil temperature AA5 M-7
sensor
CN24 DT-T 2 Transmission valve oil temperature sensor AC5 M-7
CNS1 DT-T (Brown) 12 Intermediate connector H-8
CNS2 DT-T (Green) 12 Intermediate connector B-9 B-2 H-8
CNS3 DT-T (Black) 12 Intermediate connector A-9 E-7
COM One-pin 1 Air conditioner wiring harness M3 C-7

connector
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 (Black) 12 Intermediate connector X6
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
DPC3A AMP070 18 Machine monitor P8 A-5
DPC4 AMP070 12 Machine monitor Q1 I-9 E-9 D-9 A-5
DPC6 AMP040 8 Machine monitor O7
Software rewriting connector
DPC7 X 4 (Machine monitor) N3
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
20-348 HD465-7, HD605-7

➀
Address
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 (#4) 1 Intermediate connector AG1 I-2 K-5
E13B DTHD (#4) 1 Intermediate connector AG1 H-2 K-5
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
EG4 DT-T (Brown) 12 Intermediate connector V9
ENG DT-T (Gray) 8 Intermediate connector AJ7 H-2 H-3 J-7 J-3 M-7
ER Terminal 1 Grounding C9, C8, I-1 J-8 H-8 J-7 M-8
E9, G9
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
One-pin
FS2 connector 2 Spare terminal X6
One-pin
One-pin
One-pin
One-pin
FS8 connector 2 Spare terminal X6 J-4
FSO– Terminal 1 Fuel shut-off valve – AE7 E-1
HD465-7, HD605-7 20-349

➀
Address
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
One-pin
G connector 1 Lamp (Optional for payload meter) — I-9
One-pin
G connector 1 Lamp (Optional for payload meter) — H-1
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
One-pin
H10 connector 1 Heater unit M4
One-pin
H20 connector 1 Heater unit M4
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 —
One-pin
HN connector 1 Horn switch Q8 D-9
HN1A — 1 Horn valve A4 L-9

HN1B — 1 Horn valve A4 L-9
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 (Black) 8 Intermediate connector L6 I-8 K-3 J-4 M-2
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
J03 HD30 31 Intermediate connector I2 F-6 H-6 G-5 I-5
J04 HD30 31 Intermediate connector H1 H-5 G-4 I-5
J05 HD30 31 Intermediate connector H1 F-5 H-4 G-4
J07 HD30 14 Intermediate connector H1 F-5 H-3 G-4
J08 HD30 31 Intermediate connector G1 F-5
J09 HD30 31 Intermediate connector G1 G-6 F-4 H-4 I-5
J10 HD30 31 Intermediate connector G1 G-4 F-4 H-3 G-3 I-5
JC01 DT 6 Joint connector AI6 A-4
20-350 HD465-7, HD605-7

➀
Address
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
JC15 DT 6 Joint connector AI6 H-9 L-1 L-6 M-3
JCA DT-T (Black) 8 Joint connector X5 E-1
JCB DT-T (Black) 8 Joint connector X5 K-6 C-1 A-1 C-1 G-1
JCC DT-T (Black) 8 Joint connector X5 K-6 B-1 A-2 C-1 G-1
JCD DT-T (Black) 8 Joint connector X4 K-6 B-1 A-1 C-1 G-1
JCE DT-T (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 (Black) 8 Joint connector V3 K-8 A-3 F-1 F-1 I-1
JT1 DT-T 6 Joint connector AD7 J-1
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 1 Rear view monitor (Optional) N7 I-9

connector
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
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
HD465-7, HD605-7 20-351

➀
Address
Con- Type Num-
3-dimen-
O9
O9
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
One-pin
PL06 connector 1 Fog lamp (Optional) D1 J-1
PL07 Terminal 1 Grounding C2 K-1

PM1 MIC 21 VHMS wiring harness T9 D-8, D-7
E-9
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

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

color)
PM11 MIC 21 Intermediate connector V9
PMLA DT-T (Gray) 12 Intermediate connector H9 I-3
PMPR PACKARD 3 Fuel pump pressure sensor AF5 C-1 I-7
PMRA DT-T 6 Intermediate connector D8
POW HD30 21 Intermediate connector AJ7 F-4 H-4 J-7
PR01 M 2 Right head lamp (LOW) A5 K-9
PR02 M 2 Right head lamp (HIGH) A4 J-9
PR03 One-pin 1 Clearance lamp A5 K-9

connector
PR04 One-pin 1 Clearance lamp A5 K-9
connector
One-pin
PR05 connector 1 Turn signal A5 K-9
One-pin
PR06 connector 1 Fog lamp (Optional) A6 J-9
PR07 Terminal 1 Grounding A4 K-8

PSOL DT-T 2 Parking brake solenoid L6 L-3
20-352 HD465-7, HD605-7

➀
Address
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

One-pin
PWR connector 1 Power window motor (Right) C7 F-1
One-pin
R connector 1 Lamp (Optional for payload meter) J-9
One-pin
R connector 1 Lamp (Optional for payload meter) H-1
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
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
Green outside pilot lamp relay of payload
R43 Relay 5 meter AD2 A-5
Yellow outside pilot lamp relay of payload
R44 Relay 5 meter AD2 A-5
HD465-7, HD605-7 20-353

➀
Address
R45 Relay 5 Red outside pilot lamp relay of payload AD1 A-5
meter
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
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
One-pin
RL2 connector 1 Room lamp 2 G9
RP DT-T 6 Intermediate connector A6 K-8

RPR PACKARD 3 Fuel rail pressure sensor AI6 C-1
RT2 Terminal 1 Emergency steering timer M4
RTL DT-T 6 Retarder potentiometer P8 C-9
S01 DT-T 2 Service brake switch B7 G-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 N-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 H-9
SF1 DT-T (Green) 12 Shift lever R9 B-9 B-2
SF2 DT-T 2 Shift lever Q9 J-5
SIG HD30 31 Intermediate connector AJ7 F-6 H-4 J-7
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 5 S-NET monitor T1 A-9

14S
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
20-354 HD465-7, HD605-7

➀
Address
Con- Type Num-
3-dimen-
SPA2 DT-T 12 Spare connector 2
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
Suspension oil pressure sensor(FL)
SUFL DT-T 3 (Optional) H1 H-1 K-5
Suspension oil pressure sensor(FR)
SUFR DT-T 3 (Optional) B7 G-9 K-6
Suspension oil pressure sensor(RL)
SURL DT-T 3 (Optional) L8 K-5 K-5
Suspension oil pressure sensor(RR)
SURR DT-T 3 (Optional) J9 K-5 K-5
T01 DT-T 2 Fuel level gauge sensor G9 I-9

T02 DT-T 6 Retarder oil temperature sensor H9 J-8
T05 Terminal 1 Grounding I9 K-1
T1 Terminal 1 Grounding AC9 I-3
One-pin
TG connector 1 Tachograph S9
One-pin
TG2 connector 1 Tachograph S9
TIMG PACKARD 3 Timing rail actuator AG9 D-1

TM2 HD30 21 Intermediate connector AD8 H-5 J-4
TM3 HD30 31 Intermediate connector AD8 H-5
TMF DT-T 2 Transmission oil filter sensor J3 I-9
TPR PACKARD 3 Timing rail pressure sensor AI6 C-1
TR — 6 Brake lamp timer X7 E-1
VHM DT-T (Black) 8 Intermediate connector C2
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
HD465-7, HD605-7 20-355

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

➀
HD465-7, HD605-7 20-357

➀
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
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(ENG MODE)
Related engine control system ................................................................................................................... 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 (KX) .................................................. 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

➀
[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) Engine is still preheated after preheating time ................................................................ 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

➀
TROUBLESHOOTING
WHITE
HD465-7, HD605-7 20-403

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

➀
TROUBLESHOOTING RELATED ENGINE CONTROL SYSTEM
HD465-7, HD605-7 20-405

➀
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.

without turning starting switch ON
SP1 (male), SP2 (male) Resistance
Defective engine speed sen-
1 sor Between – 1 k – 2 kΩ
(Internal trouble) Between – Max. 10 Ω
Between – Max. 10 Ω
Between – chassis ground Min. 10 MΩ
Damage of engine speed
2 Check engine speed sensor directly.
sensor
Disconnection in wiring har- Resistance Max. 10 Ω
SP1 (female)
ness
SP1 (female)
SP2 (female)
Possible causes Resistance Max. 10 Ω
SP2 (female)
and standard value
in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit of wiring harness between ECMA
(female) – SP1 (female) with wiring har- Resistance Min. 1 MΩ
ness around it
ness (female) – SP1 (female) with wiring har- Resistance Min. 1 MΩ
4
(with another wiring harness around it
ness around it
ness around it
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective engine controller Between – 1 k – 2 kΩ
Between , – chassis ground Min. 1 MΩ
Between – 1 k – 2 kΩ
Between , – chassis ground Min. 1 MΩ
20-410 HD465-7, HD605-7

➀
Circuit diagram related to engine speed sensor
HD465-7, HD605-7 20-411

➀
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)
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
CALL C132KX ENG (Engine controller system)
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

➀
[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
CALL03 C135KX ENG (Engine controller system)
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

➀
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)
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 (KX)

Trouble Abnormality in FM throttle: Out of input signal range (KX)
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

➀
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
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

➀
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) Engine is still preheated after preheating time
Action code Error code Controller code Failure in preheating

Trouble
Not set Not set ENG b) Engine is still preheated after preheating time
Contents of trouble • Engine is still preheated after preheating time
Problem that
• Engine is still preheated after preheating time
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

➀
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)
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 → F gear shift abuse 1 • Mistake in operation or setting (KM) ...................................... 20-509
[15E7KM] R → 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 ECMV • See separate list (L1)......................................................................... 20-519
[15SBMA] R clutch ECMV • Malfunction (MA).................................................................................... 20-520
[15SCL1] Hi clutch ECMV • See separate list (L1)........................................................................ 20-521
[15SCMA] Hi clutch ECMV • Malfunction (MA) ................................................................................... 20-522
[15SDL1] Lo clutch ECMV • Seee separate list (L1) ..................................................................... 20-523
[15SDMA] Lo clutch ECMV • Malfunction (MA) .................................................................................. 20-524
[15SEL1] 1st clutch ECMV • See separate list (L1) ...................................................................... 20-525
[15SEMA] 1st clutch ECMV • Malfunction (MA).................................................................................. 20-526
[15SFL1] 2nd clutch ECMV • See separate list (L1) ..................................................................... 20-527
[15SFMA] 2nd clutch ECMV • Malfunction (MA) ................................................................................ 20-528
[15SGL1] 3rd clutch ECMV • See separate list (L1) ...................................................................... 20-529
[15SGMA] 3rd clutch ECMV • Malfunction (MA) ................................................................................. 20-530
[15SHL1] 4th clutch ECMV • See separate list (L1) ......................................................................... 20-531
[15SHMA] 4th clutch ECMV • Malfunction (MA) ................................................................................. 20-532
[15SJL1] Lockup clutch ECMV • 15SJ (L1) ...................................................................................... 20-533
[15SJMA] Lockup clutch ECMV • 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

➀
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] Failure of 4th clutch flow sensor valve (Command is Holding pressure, fill switch is OFF,
and slip is not sensed): 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

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

★ For details of this page, see page 90-19.
HD465-7, HD605-7 20-503

➀


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

KA Disconnection in wiring L0 Fill signals at two or more channels which are not set as combi-
nation are turned ON at the same time.
KK Source voltage reduction/ L2 Fuel pressure is above maxim specified value.

input
KQ Type select signal incon- L3 Object part is uncontrollable.

sistency
KZ Disconnection or short cir- LC rpm signals in two systems are inconsistent.

cuit
MW Sliding
NS Overheat
HD465-7, HD605-7 20-505

➀
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 EPOCV, 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 EPOCV de- 3) Connect T-adapter.
1
fective Between CN20 (male) and Resistance 15 – 25 Ω
Between CN20 (male) , and chassis
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 Ω
in normal state CN20 (female)
contact)
Wiring harness between ATC2 (female) and
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 15 – 25 Ω
and ATC2 (female)
20-506 HD465-7, HD605-7

➀
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

➀
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 Ω
and Filter is clogged. Resistance Min. 1 MΩ
Possible causes 2) Disconnect connectors ATC5A, TNF, and CN-10.
and standard value Disconnection in wiring har- 3) Connect T-adapter.
in normal state ness Wiring harness between ATC5A (female)
3 Resistance Max. 1 Ω
and TMF (female)
contact)
Wiring harness between CJH1 (female)
and TMF (female)
2) Disconnect connectors ATC5A and ATC3A.
4
fective Between ATC5A Filter is normal. Voltage Max. 1 V
(female) and
chassis ground Filter is clogged. Voltage 20 – 30 V
20-508 HD465-7, HD605-7

➀
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

➀
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 EPOCV, 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.
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 EPOCV defective
Between CN10 (male) and Resistance 15 – 25 Ω
ground
Possible causes
ness
contact)
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-510 HD465-7, HD605-7

➀
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 EPOCV, the value calculated from the signals of the transmis-
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 EPOCV defective
ground
Possible causes
ness
contact)
CN18 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-511

➀
TROUBLESHOOTING [15H0MW]
20-512 HD465-7, HD605-7

➀
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 EPOCV, 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 Lo clutch and pressure

1 Lo clutch EPOCV defective
ground
Possible causes
ness
contact)
CN16 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-513

➀
TROUBLESHOOTING [15J0MW]
20-514 HD465-7, HD605-7

➀
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 EPOCV, 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 1st clutch and pressure

1 1st clutch EPOCV defective
ground
Possible causes
ness
contact)
CN6 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-515

➀
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 EPOCV, the value calculated from the signals of the trans-
Contents of trouble mission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission out-
put 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 2nd clutch and pressure

1 2nd clutch EPOCV defective
ground
Possible causes
ness
contact)
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-516 HD465-7, HD605-7

➀
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 EPOCV, 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 EPOCV defective
ground
Possible causes
ness
contact)
CN12 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-517

➀
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 EPOCV, 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 EPOCV defective
ground
Possible causes
ness
contact)
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-518 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SBL1]
[15SBL1] R CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code R clutch ECMV • See separate list (L1)
Trouble
E03 15SBL1 TM (Command is OFF and fill switch is ON)
• When the output to the R clutch EPOCV 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
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-
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 MΩ
(female) and CN11 (female) , CN11 (female)
and chassis ground
3 When dis-
Between ATC5A (female) and engaged
gaged
HD465-7, HD605-7 20-519

➀
TROUBLESHOOTING [15SBMA]
[15SBMA] R CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code R clutch ECMV • Malfunction (MA)
E03 15SBMA TM sensed)
• When a signal is output to the R clutch EPOCV, 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)
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-520 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SCL1]
[15SCL1] HI CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code Hi clutch ECMV • See separate list (L1)
Trouble
E03 15SCL1 TM (Command is OFF and fill switch is ON)
• When the output to the Hi clutch EPOCV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

1 Hi clutch fill switch defective When dis-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-521

➀
TROUBLESHOOTING [15SCMA]
[15SCMA] HI CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code Hi clutch ECMV • Malfunction (MA)
E03 15SCMA TM sensed)
• When a signal is output to the Hi clutch EPOCV, 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 Disconnection in wiring har- 3) Connect T-adapter.
and standard value 2 ness Wiring harness between ATC2 (female) and
in normal state (Disconnection or defective Resistance Max. 1 Ω
CN18 (female)
contact)
CN18 (female)
sensor
4
fective
and ATC2 (female)
20-522 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SDL1]
[15SDL1] LO CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code Lo clutch ECMV • See separate list (L1)
Trouble
E03 15SDL1 TM (Command is OFF and fill switch is ON)
• When the output to the Lo clutch EPOCV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

1 Lo clutch fill switch defective When dis-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-523

➀
TROUBLESHOOTING [15SDMA]
[15SDMA] LO CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code Lo clutch ECMV • Malfunction (MA)
E03 15SDMA TM sensed)
• When a signal is output to the Lo clutch EPOCV, 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
and standard value 2 ness Wiring harness between ATC2 (female) and
CN16 (female)
contact)
CN16 (female)
sensor
4
fective
and ATC2 (female)
20-524 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SEL1]
[15SEL1] 1ST CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code 1st clutch ECMV • See separate list (L1)
Trouble
E03 15SEL1 TM (Command is OFF and fill switch is ON)
• When the output to the 1st clutch EPOCV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

1 1st clutch fill switch defective When dis-
Between CN7 (male) and chas- engaged
sis ground When en-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-525

➀
TROUBLESHOOTING [15SEMA]
[15SEMA] 1ST CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code 1st clutch ECMV • Malfunction (MA)
E03 15SEMA TM sensed)
• When a signal is output to the 1st clutch EPOCV, the signal from the fill switch is kept OFF and the
Contents of trouble value calculated from the signals of the transmission input shaft speed sensor, transmission intermedi-
ate 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

ground
Possible causes
ness
contact)
CN6 (female)
sensor
4
fective
and ATC2 (female)
20-526 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SFL1]
[15SFL1] 2ND CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code 2nd clutch ECMV • See separate list (L1)
Trouble
E03 15SFL1 TM (Command is OFF and fill switch is ON)
• When the output to the 2nd clutch EPOCV 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-
sis ground When en-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-527

➀
TROUBLESHOOTING [15SFMA]
[15SFMA] 2ND CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code 2nd clutch ECMV • Malfunction (MA)
E03 15SFMA TM sensed)
• When a signal is output to the 2nd clutch EPOCV, the signal from the fill switch is kept OFF and the
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)
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-528 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SGL1]
[15SGL1] 3RD CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code 3rd clutch ECMV • See separate list (L1)
Trouble
E03 15SGL1 TM (Command is OFF and fill switch is ON)
• When the output to the 3rd clutch EPOCV 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-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-529

➀
TROUBLESHOOTING [15SGMA]
[15SGMA] 3RD CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code 3rd clutch ECMV • Malfunction (MA)
E03 15SGMA TM sensed)
• When a signal is output to the 3rd clutch EPOCV, the signal from the fill switch is kept OFF and the
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)
CN12 (female)
sensor
4
fective
and ATC2 (female)
20-530 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SHL1]
[15SHL1] 4TH CLUTCH ECMV • SEE SEPARATE LIST (L1)
Action code Error code Controller code 4th clutch ECMV • See separate list (L1)
Trouble
E03 15SHL1 TM (Command is OFF and fill switch is ON)
• When the output to the 4th clutch EPOCV 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-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-531

➀
TROUBLESHOOTING [15SHMA]
[15SHMA] 4TH CLUTCH ECMV • MALFUNCTION (MA)
Action code Error code Controller code 4th clutch ECMV • Malfunction (MA)
E03 15SHMA TM sensed)
• When a signal is output to the 4th clutch EPOCV, the signal from the fill switch is kept OFF and the
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)
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-532 HD465-7, HD605-7

➀
TROUBLESHOOTING [15SJL1]
[15SJL1] LOCKUP CLUTCH ECMV • 15SJ (L1)
Action code Error code Controller code Lockup clutch ECMV • 15SJ (L1)
Trouble
E03 15SJL1 TM (Command is OFF and fill switch is ON)
• When the output to the lockup clutch EPOCV is turned OFF, the signal from the fill switch is kept ON
Contents of trouble
and the clutch is not disengaged.
• 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-
gaged
Possible causes
harness
Min. 1 MΩ
and chassis ground
3 When dis-
gaged
HD465-7, HD605-7 20-533

➀
TROUBLESHOOTING [15SJMA]
[15SJMA] LOCKUP CLUTCH ECMV • 15SJ (MA)
Action code Error code Controller code Lockup clutch ECMV • 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 EPOCV, 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 EPOCV 3) Connect T-adapter.
1
defective Between CN20 (male) and Resistance 15 – 25 Ω
ground
2) Disconnect connector ATC5A and CN20.
Possible causes
ness
contact)
CN20 (female)
sensor
4
fective
and ATC2 (female)
20-534 HD465-7, HD605-7

➀
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
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
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
3) Check the relay.
Apply 24 V between
tween and .
Possible causes
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 Ω
and Air cleaner is clogged. Resistance Min. 1 MΩ
2) Disconnect connectors ATC3A and R32.
ness Wiring harness between ATC3A (female)
and R32 (female)
contact)
Wiring harness between ATC3A (female)
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 MΩ
(female) and FR01 (female)
, FR01 (female)
2) Disconnect connectors ATC3A.
Transmission controller de- 3) Insert T-adapter.
6 4) Turn the starting switch ON.
fective
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

➀
TROUBLESHOOTING [AA10NX]
20-540 HD465-7, HD605-7

➀
TROUBLESHOOTING [AB00MA]
[AB00MA] ALTERNATOR • MALFUNCTION (MA)
Action code Error code Controller code Alternator • Malfunction (MA)

Trouble
E01 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

➀
TROUBLESHOOTING [AB00MA]
20-542 HD465-7, HD605-7

➀
TROUBLESHOOTING [B@BCZK]
[B@BCZK] LOWERING OF RADIATOR WATER • LOWERING OF LEVEL (ZK)

Trouble Lowering of radiator water • Lowering of level (ZK)
E01 B@BCZK TM
Contents of trouble • The radiator water level switch signal circuit is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, the engine may overheat.
appears on machine

• The radiator water level is normal.
Lowering of radiator water
1
level ★ If the radiator water level is low, check around the engine and radiator
for water leakage before adding water.
2) Disconnect connector FL01.
Radiator water level switch
2 Radiator water level is
defective Resistance Max. 1 Ω
Between FL01 (male) normal.
and Radiator water level is
low.
Possible causes 2) Disconnect connectors ATC5A and FL01.
in normal state ness
3 Wiring harness between ATC5A (female)
and FL01 (female)
contact)
Wiring harness between FL01 (female) and
chassis ground
Transmission controller de- 5) Turn the starting switch ON.
3
fective
Radiator water level is
Between ATC5A (fe- normal. Voltage Max. 1 V
male) and chassis
ground Radiator water level is
Voltage 20 – 30 V
low.
HD465-7, HD605-7 20-543

➀
TROUBLESHOOTING [D1B0KZ]
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT
Action code Error code Controller code Transmission controller cutout relay • Disconnection or short cir-
Trouble cuit (KZ)
E03 D1B0KZ TM (Disconnection or short circuit)
Contents of trouble • Abnormal voltage is generated in the transmission cutout relay circuit.
• The controller turns the transmission cutout relay OFF.
• The controller sets the gear in Neutral.
Problem that
appears on machine

Relay (R15)
No
When transmission cutout relay (R15) is is normal.
replaced, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay defective
3) Check the relay.
Apply 24 V between
between and .

and standard value 2) Disconnect connectors ATC1 and R15.
Disconnection in wiring har- Wiring harness between ATC1 (female) and
2 R15 (female)
contact) Between R15 (female) and chassis ground Resistance Max. 1 Ω
Wiring harness between fuse BT2
Voltage between ATC1
terminal (22) and ATC1 (female) 20 – 30 V
and chassis ground

2) Disconnect connectors ATC1 and R15.
3 Grounding fault Resistance value be-
Min. 1 MΩ
male) and R15 (female) , R15 (female)
and chassis ground
4
fective When error code to turn transmis-
Between sion cutout relay OFF is displayed Voltage Max. 1 V
ATC1 (Example: 1500LO)
and ,
When error code is not displayed Voltage 20 – 30 V
20-544 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 ,
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 sets the gear in Neutral.
Problem that
appears on machine
Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) 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 EPOCV is turned ON, the clutch is engaged but the signal from
Contents of trouble
the 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-
gaged
Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21.
and standard value ness
2 3) Connect T-adapter.
in normal state (Disconnection or defective
and CN21 (female)
3 When dis-
gaged
HD465-7, HD605-7 20-557

➀
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 EPOCV 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-
gaged
and CN19 (female)
3 When dis-
gaged
20-558 HD465-7, HD605-7

➀
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 EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.

1 Lo clutch fill switch defective When dis-
gaged
and CN17 (female)
3 When dis-
gaged
HD465-7, HD605-7 20-559

➀
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 EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble

1 1st clutch fill switch defective When dis-
sis ground When en-
gaged
and CN7 (female)
3 When dis-
gaged
20-560 HD465-7, HD605-7

➀
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 EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble

2nd clutch fill switch defec-
1 When dis-
sis ground When en-
gaged
and CN9 (female)
3 When dis-
gaged
HD465-7, HD605-7 20-561

➀
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 EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble

3rd clutch fill switch defec-
1 When dis-
gaged
and CN13 (female)
3 When dis-
gaged
20-562 HD465-7, HD605-7

➀
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 EPOCV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble
switch is not turned ON.

1 R clutch fill switch defective When dis-
gaged
and CN11 (female)
3 When dis-
gaged
HD465-7, HD605-7 20-563

➀
TROUBLESHOOTING [DDTPKA]
[DDTPKA] FAILURE OF 4TH CLUTCH FLOW SENSOR VALVE : DISCONNECTION (KA)
Action code Error code Controller code Failure of 4th clutch flow sensor valve : Disconnection (KA)
E03 DDTPKA TM sensed)
• When the output to the 4th clutch EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble

4th clutch fill switch defec-
1 When dis-
gaged
and CN15 (female)
3 When dis-
gaged
20-564 HD465-7, HD605-7

➀
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.
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
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
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
TROUBLESHOOTING [DLF2KA]
[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
(Disconnection or defective and CN4 (female)
contact)
and CN4 (female)
fective
HD465-7, HD605-7 20-585

➀
TROUBLESHOOTING [DLF2LC]
[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

➀
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 EPOCV, 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)
and CN20 (female)
3
fective
and ATC2 (female)
20-590 HD465-7, HD605-7

➀
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 EPOCV, 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 MΩ
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

➀
[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 EPOCV, 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.
in normal state ness Wiring harness between ATC2 (female)
and CN18 (female)
contact)
and CN18 (female)
3
fective
and ATC2 (female)
20-592 HD465-7, HD605-7

➀
[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 EPOCV, 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

➀
20-594 HD465-7, HD605-7

➀
[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 EPOCV, any current does not flow.
Problem that • The gear is set in Neutral during travel.

ground
CN16 (female)
contact)
male) and CN16 (female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-595

➀
[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 EPOCV, 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

➀
HD465-7, HD605-7 20-597

➀
[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 EPOCV, any current does not flow.

ground
CN6 (female)
contact)
CN6 (female)
3
fective
ATC2 (female)
20-598 HD465-7, HD605-7

➀
[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 EPOCV, 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

➀
[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 EPOCV, any current does not flow.

ground
CN8 (female)
contact)
CN8 (female)
3
fective
ATC2 (female)
20-600 HD465-7, HD605-7

➀
[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 EPOCV, an abnormally large current flows, or some current
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-601

➀
[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 EPOCV, any current does not flow.

ground
CN12 (female)
contact)
CN12 (female)
3
fective
ATC2 (female)
20-602 HD465-7, HD605-7

➀
[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 EPOCV, an abnormally large current flows, or some current
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

➀
[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 EPOCV, any current does not flow.

ground
CN10 (female)
contact)
CN10 (female)
3
fective
ATC2 (female)
20-604 HD465-7, HD605-7

➀
[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 EPOCV, 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

➀
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 EPOCV, any current does not flow.

ground
CN14 (female)
contact)
CN14 (female)
3
fective
ATC2 (female)
20-606 HD465-7, HD605-7

➀
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 EPOCV, an abnormally large current flows, or some current
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female) ,
HD465-7, HD605-7 20-607

➀
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 Ω
(female) and
Possible causes Fuel level: When EMPTY Resistance 74 – 100 Ω
and standard value
2) Disconnect connectors ATC3B and T01.
harness
Min. 1 MΩ
(female) and T01 (female) , T01 (female)
and chassis ground
20-608 HD465-7, HD605-7

➀
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)
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
[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

➀
TROUBLESHOOTING REAR SUSPENSION CYLINDER
[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

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
20-704 HD465-7, HD605-7

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
HD465-7, HD605-7 20-705

➀


panel panel panel
Problem that
appears on machine

1
• Disconnection
• Short circuit
3
side.
side.
5
side.
20-706 HD465-7, HD605-7

➀

TROUBLE CODE TABLE

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 20-707

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 connector BTC1 and fuse BT3 terminal .
4) Connect the connector and fuse BT3 terminal .
Voltage between
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 SUFR.
and SUFR (female)
and SUFR (female)
and SUFR (female)
2) Disconnect connectors BRC1 or BRC3A and SUFR.
Wiring harness between Resistance between BRC3A
2 BRC3A (female) and (female) , SUFR (female) Min. 1 M Ω
SUFR (female) and chassis ground
and standard value
in normal state Wiring harness between Resistance between BRC1
BRC1 (female) and (female) , SUFR (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and SUFR.
3
Wiring harness between Voltage between BRC3A
BRC3A (female) and (female) , SUFR (female) Max. 1 V
2) Disconnect connector SUFR.
Front accumulator oil pres- 4) Connect the connector.
4
Between SUFR and Voltage 20 – 30 V
Between SUFR and Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC1 and BRC3A.
Between BRC1 and BRC3A Voltage 20 – 30 V
BRC3A and Voltage 1.0 – 4.6 V
20-728 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-729

➀
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.

Voltage between
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and SUFR.
and SUFR (female)
and SUFR (female)
and SUFR (female)
2) Disconnect connectors BRC1 or BRC3A and SUFR.
2 BRC3A (female) and (female) , SUFR (female) Min. 1 M Ω
and standard value
BRC1 (female) and (female) , SUFR (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and SUFR.
3
BRC3A (female) and (female) , SUFR (female) Max. 1 V
2) Disconnect connector SUFR.
4
Between SUFR and Voltage 20 – 30 V
Between SUFR and Voltage 1.0 – 4.6 V
20-730 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-731

➀
[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.

Voltage between
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and SUFL.
and SUFL (female)
and SUFL (female)
and SUFL (female)
2) Disconnect connectors BRC1 or BRC3A and SUFL.
2 BRC3A (female) and (female) , SUFL (female) Min. 1 M Ω
SUFL (female) and chassis ground
and standard value
BRC1 (female) and (female) , SUFL (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) and (female) , SUFL (female) Max. 1 V
2) Disconnect connector SUFL.
4
Between SUFL and Voltage 20 – 30 V
Between SUFL and Voltage 1.0 – 4.6 V
20-732 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-733

➀
[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.

Voltage between
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and SUFL.
and SUFL (female)
and SUFL (female)
and SUFL (female)
2) Disconnect connectors BRC1 or BRC3A and SUFL.
2 BRC3A (female) and (female) , SUFL (female) Min. 1 M Ω
and standard value
BRC1 (female) and (female) , SUFL (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) and (female) , SUFL (female) Max. 1 V
2) Disconnect connector SUFL.
4
Between SUFL and Voltage 20 – 30 V
Between SUFL and Voltage 1.0 – 4.6 V
20-734 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-735

➀
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 .
Voltage between
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
BRC1 (female) and (female) , ACCF (female) Min. 1 M Ω
2) Disconnect connectors BRC3A and ACCF.
3
BRC3A (female) and (female) , ACCF (female) Max. 1 V
2) Disconnect connector ACCF.
4
Between ACCF and Voltage 20 – 30 V
Between ACCF 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

Voltage between
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
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
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 4) Connect the connector.
defective
Between S04 (female) and Resistance 15 – 35 Ω
Between S04 (female) , and chassis
ground
Possible causes 2) Disconnect connectors BRC1 and S04.
2 Wiring harness between BRC1 (female)
and S04 (female)
contact)
Wiring harness between S04 (female) and
chassis ground
Between BRC1 (female) and chassis
ground
20-754 HD465-7, HD605-7

➀
[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 4) Connect the connector.
defective
Between S05 (female) and Resistance 15 – 35 Ω
Between S05 (female) , and chassis
ground
Possible causes 2) Disconnect connectors BRC1 and S05.
and S05 (female)
contact)
Wiring harness between S05 (female) and
chassis ground
ground
HD465-7, HD605-7 20-755

➀
[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.
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.
ground
20-758 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-759

➀
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- 4) Connect the connector.
1
ing valve solenoid defective 5) Turn the starting switch ON.
Between RETV (female) and Resistance 10 – 30 Ω
Between RETV (female) , and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and RETV.
and RETV (female) .
contact)
and RETV (female) .
2) Disconnect connector BRC.
Between BRC2 (female) and Resistance 10 – 30 Ω
20-760 HD465-7, HD605-7

➀
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) and RETV (female) Min. 1 M Ω
cuit in wiring harness , RETV (female)
.
and chassis ground.
Wiring harness between BRC (female) and RETV (fe-
male) and wiring harness between BRC (female) Min. 1 M Ω
and RETV (female)
HD465-7, HD605-7 20-761

➀
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) ,
(female) and RETV (female) Max. 1 V
RETV (female) and
.
chassis ground.
20-762 HD465-7, HD605-7

➀
TROUBLESHOOTING [DX13KA]
[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
defective
Between HEPC (female) and Resistance 15 – 20 Ω
Between HEPC (female) , and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and HEPC.
and standard value
and HEPC (female) .
contact)
and HEPC (female) .
19. Between BRC2 (female) and Resistance 15 – 20 Ω
HD465-7, HD605-7 20-763

➀
TROUBLESHOOTING [DX13KB]
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT (KB)

Trouble Grounding fault in output circuit of hoist EPC valve (A_OUT3):
E03 DX13KB BK Short circuit (KB)
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 select valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid 5) Turn the starting switch ON.
1
defective
ground
and standard value Resistance value be-
Grounding fault or short cir- (female) tween BRC2 (female)
2 and HEPC (female) Min. 1 M Ω
cuit in wiring harness , HEPC (female)
.
and chassis ground.
Wiring harness between BRC (female) and HEPC (fe-
male) and wiring harness between BRC (female) Min. 1 M Ω
and HEPC (female)
20-764 HD465-7, HD605-7

➀
[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 select valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid 4) Connect the connector.
defective
ground
and standard value Short circuit with power Voltage between
source in wiring harness BRC2 (female) ,
2 (female) and HEPC (female) Max. 1 V
(Contact with power source HEPC (female) and
.
wiring harness) chassis ground.
Voltage between
Wiring harness between BRC2
BRC2 (female) ,
(female) and HEPC (female) Max. 1 V
HEPC (female) and
.
chassis ground.
HD465-7, HD605-7 20-765

➀
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) ,
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)
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

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO PAYLOAD METER
SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802 HD465-7, HD605-7

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO PAYLOAD METER
HD465-7, HD605-7 20-803

➀
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
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
Grounding fault in wiring Min. 1 M Ω
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)
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

➀
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) When lamp switch is set in 2nd position, head lamp "Lo" does not light up.................. 20-949
f) Head lamp "Hi" beam does not light up ........................................................................ 20-950
g) Head lamp "Lo" beam does not light up........................................................................ 20-951
h) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-952
j) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-953
MON-11 Power window does not operate normally.......................................................................... 20-955
a) Operating left side does not ......................................................................................... 20-955
b) Operating right side does not ....................................................................................... 20-956
★ For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM
Mode).
20-902 HD465-7, HD605-7

➀
TROUBLESHOOTING SYSTEM DIAGRAM RELATED TO MONITOR
SYSTEM DIAGRAM RELATED TO MONITOR

★ For details of this page, see page 90-21.
20-904 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 20-905

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

➀
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

➀
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 .
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
2) Disconnect connector DPC2B.
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) When lamp switch is set in 2nd position, head lamp "Lo" does not light up

Trouble e) When lamp switch is set in 2nd position, head lamp "Lo" does
Not set Not set Not set not light up
Contents of trouble • When the lamp switch is set in the 2nd position, head lamp "Lo" does not light up.
Problem that
• When the lamp switch is set in the 2nd position, head lamp "Lo" does not light up.
appears on machine
wiring harness.)
Related information

When hazard relay 2 (R30) is re- No Relay R30
placed, is failure repaired? Yes Relay R30
3) Check the relay.
Head lamp "Lo" relay (R30)
2
and standard value 2) Disconnect connector R30.
in normal state 3) Check the relay.
Apply 24 V between
tween and .
2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1
terminals and
Wiring harness between PL1 (female) and
chassis ground
Disconnection in wiring har- Wiring harness between PR1 (female) and
3 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)
HD465-7, HD605-7 20-949

➀
f) Head lamp "Hi" beam does not light up

Trouble
Not set Not set Not set f) Head lamp "Hi" beam does not light up
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 "Hi" relay (R29)
2
3) Check the relay.
Possible causes 4) Apply voltage between R29 (male) and .
tween and .
terminals 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
branching point of wiring harness
R29 (female)
20-950 HD465-7, HD605-7

➀
g) Head lamp "Lo" beam does not light up

Trouble
Not set Not set Not set g) 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
and standard value
terminals and
in normal state
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)
fuse BT1 terminal
Wiring harness fuse BT1 terminal and PL1
(female) , PR1 (female)
HD465-7, HD605-7 20-951

➀
h) Head lamp cannot be set to "Hi" or "Lo"

Trouble
Not set Not set Not set h) Head lamp cannot be set to "Hi" or "Lo"
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 "Lo" 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)
20-952 HD465-7, HD605-7

➀
j) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up

Trouble j) 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".
HD465-7, HD605-7 20-953

➀
20-954 HD465-7, HD605-7

➀
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
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
HD465-7, HD605-7 20-955

➀
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
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
20-956 HD465-7, HD605-7

➀
HD465-7, HD605-7 20-957

➀
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEMS (H MODE)
H-1 Machine does not start ................................................................................................................... 20-1002

H-2 Machine does not travel smoothly (machine jerks) ........................................................................ 20-1004
H-3 Lock-up clutch cannot be disengaged (engine stalls) .................................................................... 20-1004
H-4 Excessive shock when starting or shifting...................................................................................... 20-1005
H-5 Transmission does not shift up....................................................................................................... 20-1005
a. Does not shift up ....................................................................................................................... 20-1005
b. Does not shift up ....................................................................................................................... 20-1005
H-6 Machine lacks power or speed when traveling............................................................................... 20-1006
a. Abnormality at all speed ranges................................................................................................ 20-1006
b. Torque converter lock-up does not engage............................................................................... 20-1007
c. Abnormality at specific speed ranges ....................................................................................... 20-1008
H-7 Time lag is excessive when starting or shifting gear ...................................................................... 20-1010
H-8 Torque converter oil temperature is high ........................................................................................ 20-1012
H-9 Torque converter oil pressure is low............................................................................................... 20-1013
H-10 Front brake is ineffective, or effective only on one side ................................................................. 20-1014
H-11 Rear brake is ineffective, or effective only on one side .................................................................. 20-1015
H-12 Steering wheel is heavy ................................................................................................................. 20-1016
H-13 Steering wheel does not work ........................................................................................................ 20-1017
H-14 Steering wheel vibrates .................................................................................................................. 20-1017
H-15 Hoist cylinder lacks lifting force (lifting speed) .............................................................................. 20-1018
H-16 Hoist cylinder does not work .......................................................................................................... 20-1019
H-17 Excessive hydraulic drift of dump body .......................................................................................... 20-1020
HD465-7, HD605-7 20-1001

➀
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 E-POCV solenoid valve

Causes
Defective operation of E-POCV valve

Pump does not drive (defective PTO)
Air sucked in at suction side of pump
Defective speed sensor function

Damage inside torque converter
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
20-1002 HD465-7, HD605-7

➀
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 20-1003

➀
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 E-POCV solenoid valve
Defective actuation of lock-up E-POCV 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 E-POCV valve is normal
4 Operation of lock-up E-POCV solenoid valve is normal
20-1004 HD465-7, HD605-7

➀
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 E-POCV pressure control valve spool and pressure detec-
tor valve spool, or defective operation of the E-POCV 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 E-POCV 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 20-1005

➀
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling
a. Abnormality at all speed ranges

• Is the oil level in the transmission case cor-
rect?
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
• Is there any external oil leakage from the
piping or valve joints?
Defective operation of torque converter relief valve, deteriorated spring

• Is there any dragging of the parking brake,
Drop in set pressure of main relief valve (torque converter valve)

service brake, or retarder?
• Is any failure code related power trains dis-
Cooler, piping beyond torque converter outlet port damaged

played?
Damage inside torque converter (turbine rivet broken)

Checking for abnormalities
• Engine high idring speed
• Torque converter stall speed
Torque converter lock-up does not engage

• Machine travel speed Causes
• Transmission clutch pressure
Defective torque converter freewheel

• Torque converter lock-up pressure
Drop in performance of engine

• Main relief pressure
Crogged strainer
Defective pump
a b c d e f g h i j k
Remedy A
C ✕ ✕ A ✕
No. ✕
✕ ✕ ✕
Problems See TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
2 Torque converter stall speed is high
3 Torque converter stall speed is low

Low at every speed range
4
(Item 2 abnormal)
Set pressure of Indicator is unstable and fluctuates
5
transmission is low excessively
Low after entering torque converter See TORQUE CONVERTER LOCK-UP DOES
6
lock-up NOT ENGAGE.
Hydraulic pressure at torque converter inlet port is low
7
(Items 4 – 6 normal)
Hydraulic pressure at torque converter outlet port is low
8
(Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of
9
transmission case
10 Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops
20-1006 HD465-7, HD605-7

➀
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 E-POCV solenoid valve spool

• Main travel speed
Defective operation of lock-up E-POCV 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 20-1007

➀
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 E-POCV except 2nd.
(1) F2 is normal, but F1 is defective or only F1 is defective

2
(2) Returns to normal when replaced with any E-POCV except 1st.
(1) F1 and F2 are normal, but F3 is defective

3
(2) Returns to normal when replaced with any E-POCV except H.
(1) F1, F2 and F3 are normal, but F4 is defective

4
(2) Returns to normal when replaced with any E-POCV except 3rd.
(1) F1 – F5 are normal, but F6 is defective

5
(2) Returns to normal when replaced with any E-POCV except 4th.
(1) F3, F5, and F7 are normal, but others are defective
6
(2) Returns to normal when replaced with any E-POCV except L.
(1) Only R is defective

7
(2) Returns to normal when replaced with any E-POCV except R.
★ Remove all the mud and dirt from around the E-POCV, and clean it before replacing.
★ After replacing, tighten the E-POCV mounting bolts to the specified tightening torque.
E-POCV mounting bolt : 8.0 – 10.0 Nm {0.8 – 1.0 kgm}
20-1008 HD465-7, HD605-7

➀
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 E-POCV
✕
Defective operation of L clutch E-POCV
✕
Defective operation of 4th clutch E-POCV
✕
Defective operation of 3rd clutch E-POCV
✕
Defective operation of 2nd clutch E-POCV
✕
m
Defective operation of 1st clutch E-POCV
✕
Defective operation of R clutch E-POCV
➀
H-6
20-1009
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
20-1010 HD465-7, HD605-7

➀
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 E-POCV
✕
Defective operation of L clutch E-POCV
✕
Defective operation of 4th clutch E-POCV
✕
Defective operation of 3rd clutch E-POCV
✕
Defective operation of 2nd clutch E-POCV
✕
Defective operation of 1st clutch E-POCV
✕
Defective operation of R clutch E-POCV
➀
20-1011
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.
20-1012 HD465-7, HD605-7

➀
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 20-1013

➀
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
20-1014 HD465-7, HD605-7

➀
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 20-1015

➀
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
20-1016 HD465-7, HD605-7

➀
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 20-1017

➀
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
C ✕ ✕ C A ✕ ✕ A
No. ✕ ✕
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
20-1018 HD465-7, HD605-7

➀
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 20-1019

➀
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
20-1020 HD465-7, HD605-7

➀
90 OTHERS
Power train hydraulic circuit diagram ...................................90- 2

Steering and hoist hydraulic circuit diagram ........................90- 3
Brake hydraulic circuit diagram ............................................90- 5
Electrical system diagram related to transmission control ...90-19
Electrical system diagram related to monitor .......................90-21
HD465-7, HD605-7 90-1

➀
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HD465-7, HD605-7

Shop Manual HD465-7 Dan HD 605-7

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Shop Manual HD465-7 Dan HD 605-7

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SEBM027600

MACHINE MODEL SERIAL NUMBER

HD465-7 7001 and up

• HD465-7, HD605-7 mounts the SAA6D170E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ............................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY .......................................... Will be issued later

90 OTHERS ............................................................................................................................... 90-1

00-2 HD465-7, HD605-7

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Thread diameter Tightening torque