HD465 7 Shop Manual SN 7001 Up

SEBM027612
MACHINE MODEL HD465-7 HD605-7
SERIAL NUMBER 7001 and up 7001 and up
This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. HD465-7, HD605-7 mount the SAA6D170E-3 engine. For details of the engine, see the 170-3 Series Engine Shop Manual.
2006 All Rights Reserved Printed in Japan 02-06(02)
00-1
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CONTENTS
No. of page ........................................................................................................................... 01-1
01 10
GENERAL
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ................................................................. 10-1 TESTING AND ADJUSTING ............................................................................... 20-1 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1 OTHERS
20 30 90
............................................................................................................................... 90-1
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HD465-7, HD605-7
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20-195-1 20-195-2 20-195-3 20-196 20-197 20-197-1 20-197-2 20-197-3 20-197-4 20-197-5 20-197-6 20-197-7 20-197-8 20-198 20-203-1 20-203-2 20-203-3 20-203-4 20-203-5 20-203-6 20-203-7 20-203-8 20-203-9 20-203-10 20-203-11 20-203-12 20-203-13 20-203-14 20-203-15 20-203-16 20-203-17 20-203-18 20-203-19 20-203-20 20-203-21 20-203-22 20-204 20-204-1 20-204-2 20-204-3 20-205 20-206 20-207 20-301 20-302 20-303 20-304 20-305 20-306 20-307 20-308
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20-309 20-310 20-311 20-312 20-312-1 20-313 20-314 20-315 20-316 20-317 20-317-1 20-318 20-319 20-320 20-321 20-322 20-323 20-324 20-325 20-326 20-327 20-328 20-329 20-330 20-331 20-332 20-333 20-334 20-335 20-336 20-337 20-338 20-339 20-340 20-340-1 20-341 q q 20-342 q 20-343 20-344 20-345 20-346 20-347 20-348 20-349 20-350 20-351 20-352 20-353 20-354 20-355 20-355-1
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20-355-2 20-356 20-357 20-358 20-359 20-360 20-361 20-362 20-363 20-364 20-365 20-366 20-367 20-401 20-402 20-404 20-405 20-405-1 20-405-2 20-405-3 20-405-4 20-406 20-407 20-408 20-409 20-410 20-411 20-412 20-413 20-414 20-415 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-423 20-424 20-425 20-426 20-427 20-428 20-429 20-430 20-431 20-432 20-433 20-434
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HD465-7, HD605-7
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20-711 20-712 20-713 20-714 20-715 20-716 20-717 20-718 20-719 20-720 20-721 20-722 20-723 20-724 20-725 20-726 20-727 20-728 20-729 20-730 20-731 20-732 20-733 20-734 20-735 20-736 20-737 20-738 20-739 20-740 20-741 20-742 20-743 20-744 20-745 20-746 20-747 20-748 20-749 20-750 20-751 20-752 20-753 20-754 20-755 20-756 20-757 20-758 20-759 20-759-1 20-759-2
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20-760 20-761 20-762 20-762-1 20-763 20-764 20-765 20-766 20-767 20-768 20-769 20-770 20-771 20-772 20-773 20-774 20-801 20-802 20-803 20-804 20-805 20-806 20-807 20-808 20-809 20-810 20-811 20-812 20-813 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-821 20-822 20-823 20-824 20-825 20-826 20-827 20-828 20-829 20-830 20-831 20-832 20-833 20-834 20-835
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20-944 20-945 20-946 20-947 20-948 20-949 20-950 20-951 20-952 20-953 20-954 20-955 20-956 20-957 20-958 20-959 20-960 20-961 20-962 20-963 20-964 20-965 20-966 20-967 20-1001 20-1002 20-1003 20-1003-1 20-1004 20-1005 20-1006 20-1006-1 20-1006-2 20-1006-3 20-1006-4 20-1006-5 20-1006-6 20-1006-7 20-1006-8 20-1007 20-1008 20-1009 20-1010 20-1011 20-1012 20-1013 20-1014 20-1015 20-1016 20-1017 20-1018
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20-1019 20-1020 20-1021 20-1022 20-1023 20-1023-1 20-1023-2 20-1023-3 20-1023-4 20-1023-5 20-1023-6 20-1023-7 20-1023-8 20-1023-9 20-1023-10 20-1024 20-1025 20-1026 20-1027 20-1028 20-1029 20-1030 20-1031 20-1032 20-1033 20-1034 20-1035 20-1036 20-1051 20-1052 20-1053 20-1054 20-1055 20-1056 20-1057 20-1058 20-1059 20-1060 20-1061 20-1062 20-1063 20-1064 20-1065 20-1066 20-1067 20-1068 20-1069 20-1070 20-1071 20-1072 20-1073
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20-1074 20-1075 20-1076 20-1077 20-1078 20-1079 20-1080 20-1081 20-1082 20-1101 20-1102 20-1103 20-1104 20-1105 20-1106 20-1107 20-1108 20-1109 20-1110 20-1111 20-1112 20-1113 20-1114 20-1115 20-1116 20-1117 20-1118 20-1119 20-1120 20-1151 20-1152 20-1153 20-1154 20-1155 20-1156 20-1157 20-1159 20-1160 20-1161 20-1162 20-1163 20-1164 20-1165 20-1166 20-1167 20-1168 20-1169 20-1170 20-1171 20-1172 20-1173
(10) (10) (10) (10) (5) (10) (10) (10) (10) (2) (10) (2) (10) (10) (10) (10) (7) (7) (2) (7) (10) (2) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10)
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
20-1175 20-1176 20-1177 20-1178 20-1179 20-1180 20-1181 20-1182 20-1183 20-1201 20-1202 20-1203 20-1204 20-1205 20-1206 20-1207 20-1251 20-1252 20-1253 20-1254 20-1255 20-1256 20-1257 20-1258 20-1259 20-1260 20-1261 20-1262 20-1263 20-1264 20-1265 20-1266 20-1268 20-1269 20-1270 20-1271 20-1272 20-1273 20-1274 20-1275 20-1276 20-1277 20-1278 20-1279 20-1280 20-1281 20-1282 20-1283 20-1284 20-1285 20-1286
(10) (10) (10) (10) (10) (10) (10) (10) (10) (11) (11) (11) (11) (11) (11) (11) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12)
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20-1287 20-1288 20-1290 20-1291 20-1292 20-1293 20-1294 20-1295 20-1296 20-1297 20-1298 20-1299 20-1300 20-1301 20-1302 20-1303 20-1304 20-1305 20-1306 20-1307 20-1308 20-1309 20-1310 30-1 30-2 30-3 30-4 30-5 30-5-1 30-5-2 30-5-3 30-5-4 30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23
(12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (10) (10) (3) (3) (3) (10) (10) (11) (10) (3) (10) (10) (10) (10) (3) (10) (10) (3) (10) (3) (10) (3) (3) (3) (10) (10) (10)
30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74
(10) (3) (10) (10) (3) (3) (3) (3) (10) (10) (10) (3) (3) (3) (10) (3) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (3) (3) (3) (3) (10) (10) (3) (3) (3) (10) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3)
30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-113-1 30-113-2 30-113-3 30-114 30-115 30-116 30-117 30-117-1 30-117-2 30-117-3 30-118 30-119 30-120
(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (4) (10) (10) (3) (10) (3) (3) (10) (3) (3) (10) (10) (10) (3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (10) (3) (10) (10) (8) (10) (3) (10) (3) (10) (10) (8) (10) (10) (10) (10)
HD465-7, HD605-7
00-2-5
(12)
Mark
Page
Page
Page
Page
Page
Revision number
30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152
(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (3) (3) (3) (3) (4) (3) (3) (3) (3) (3) (10) (3) (3) (7) (4) (4) (10) (4) (10) (4) (4) (10) (12) (12) (12)
q 90-1 q q
90-2 90-3 90-5 90-7 90-9 90-11 90-13 90-15 90-17 90-19 90-21 90-23 90-25 90-26-1 90-26-3 90-27 90-29
Q Q q Q
(7) (7) (10) (10) (12) (12) (12) (12) HD465-7, HD605-7
00-2-6
(12)
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
00-3
SAFETY
SAFETY NOTICE
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, 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.
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
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 judgements. 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 further 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 understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance 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 component, 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

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: volume to cover all models
REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.
Safety
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
Caution
Weight
3 2 5 6
Tightening torque
Coat
Oil, water
Drain
00-6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
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, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120 hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150.
! The allowable load value is estimated to be onesixth 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

k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ! The adapter can be pushed in about 3.5 mm. ! Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ! Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ! Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ! When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
Type 1
00-8
FOREWORD
Type 2 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
Type 3 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
Disassembly
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect 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 LT-1A Part No. 790-129-9030 Qty 150 g Container Tube Main applications, features
LT-1B
790-129-9050
LT-2
09940-00030
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120
790-129-9140
Aron-alpha 201
790-129-9130
Loctite 648-50 LG-1
79A-129-9110 790-129-9010
LG-5
790-129-9080
LG-6 Gasket sealant LG-7
790-129-9020
790-129-9070
Three bond 1211 Three bond 1207B
790-129-9090
419-15-18131
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. Features: Resistance to heat and chemicals Polyethylene 50 g Used for anti-loosening and sealant container purpose for bolts and plugs. Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene Used as sealant for machined holes. 250 g container Used as heat-resisting sealant for 75 g Tube repairing engine. Quick hardening type adhesive Polyethylene Cure time: within 5 sec. to 3 min. 50 g container Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive Quick cure type Polyethylene (max. strength after 30 minutes) 2g container Used mainly for adhesion of rubbers, plastics and metals. Resistance to heat, chemicals Polyethylene Used at joint portions subject to high 50 cc container temperatures. Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. Used as sealant for various threads, pipe joints, flanges. 1 kg Can Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold 200 g Tube Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. Used as heat-resisting sealant for 100 g Tube repairing engine. Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material Used as sealing material for transfer case
00-10
FOREWORD
COATING MATERIALS
Category
Komatsu code LM-G
Part No. 09940-00051
Qty 60 g
Container Can
Main applications, features Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type
Molybdenum disulphide lubricant
LM-P
09940-00040 SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
200 g
Tube
G2-LI
Various
Various
G2-CA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Grease
Primer
Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER S or W Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can
Used for heavy load portion
400 g 16 kg
Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type Since this grease is white, it does not Can stand out against machine body. Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can Used as primer for cab side (Using limit: 4 months) Used as primer for glass side (Using limit: 4 months) Used as primer for painted surface on cab side (Using limit: 4 months) Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) Used as primer for sash (Alumite). (Using limit: 4 months) Used as adhesive for glass. (Using limit: 6 months) S is used for high-temperature season (April - October) and W for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) Used as adhesive for glass. (Using limit: 6 months) Used to seal joints of glass parts. (Using limit: 4 months) Used to seal front window. (Using limit: 6 months) Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)
400 g 16 kg
20 ml 417-926-3910 20 ml
Glass container Glass container Glass container
22M-54-27230
20 ml
22M-54-27240
150 ml
Can Adhesive for cab glass
22M-54-27250
20 ml
Glass container Ecocart (Special container) Polyethylene container Polyethylene container Polyethylene container Polyethylene container Cartridge
22M-54-27210
320 ml
Adhesive
417-926-3910
320 ml
20Y-54-39850 417-926-3920
310 ml 320 ml
Caulking material
20Y-54-55130
333 ml
22M-54-27220
333 ml
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Tightening torque Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 14.7 27 34 59 74 98 123 153 190 235 285 320 400 455 565 610 765 785 980 1150 1440 1520 1910 1960 2450 2450 3040 2890 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2 kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2 kgm 1.2 1.5 2.8 3.5 6 7.5 10 12.5 15.5 19.5 23.5 29.5 33 41 46.5 58 62.5 78 80 100 118 147 155 195 200 250 250 310 295 370
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ! In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49 Tightening torque
SAD00483
kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5
00-12
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 10 12 16
Width across flat mm 14 17 22 Nm 59 74 98 123 235 285
Tightening torque kgm 6 7.5 10 12.5 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42
Width across flat mm
Tightening torque (Nm {kgm}) Range 35 63 84 132 128 186 363 480 746 1010 {3.5 6.5} {8.5 13.5} {13.0 19.0} {37.0 49.0} {76.0 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
Varies depending on type of connector.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 36
Tightening torque (Nm {kgm}) Range 5.88 8.82 9.8 12.74 14.7 19.6 19.6 24.5 24.5 34.3 34.3 44.1 44.1 53.9 58.8 78.4 93.1 122.5 107.8 147.0 127.4 176.4 181.3 240.1 274.4 367.5 {0.6 0.9} {1.0 1.3} {1.5 2.0} {2.0 2.5} {2.5 3.5} {3.5 4.5} {4.5 5.5} {6.0 8.0} {9.5 12.5} {11.0 15.0} {13.0 18.0} {18.5 24.5} {28.0 37.5} Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 Nm 10 0 2 24 0 4 43 0 6 77 0 12 Tightening torque kgm 1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 14 Nm 802 10 0 2 12 0 2 24 0 4 36 0 5 Tightening torque kgm 0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 Nm 301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9 Tightening torque kgm 0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.20 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ! Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range 34 54 {3.5 5.5} 34 63 {3.5 6.5} 03 22 24 04 05 06 (10) (12) (14) 27 32 36 41 46 55 54 93 {5.5 9.5} 59 98 {6.0 10.0} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type
Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series 14 18 22 24 30 33 36 42 9 18UN 16 11 16UN 16 13 16UN 16 1 14UNS 3 1 12UN 16 14.3 17.5 20.6 25.4 30.2
02
19
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 number Number of strands Dia. of strands (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm2) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) Current rating (A) Applicable circuit
0.85 2 5 15 40 60 100
11 26 65 84 85 127 217
2.4 3.1 4.6 7.0 11.4 13.6 17.6
12 20 37 59 135 178 230
Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Circuits Priority Classification Primary Code Color Code 2 Color White & Red Code 3 Color White & Black Code 4 Auxiliary WL Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR RY YG Yellow & Green YL GY Green & Yellow GB LY Blue & Yellow LB WB White & Black Red & White Rellow & Red Green & White Blue & White BY RB YB GR LR
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
W White WR
B Black
B Black BW
R Red RW
Y Yellow YR
G Green GW
L Blue LW
Color White & Blue Code WG
Black & Red Red & Yellow RG
5 Color White & Green Code 6 Color Red & Blue Yellow & White Green & Blue Red & Green Yellow & Blue Green & Black Blue & Black RL YW GL
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches
1 mm = 0.03937 in
0 0 10 20 30 40 (A) 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
00-16
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42
1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62
2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83
3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03
4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24
5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44
6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64
7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85
8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05
9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775
1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040
2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304
3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568
4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832
5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096
6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361
7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625
8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889
9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 0 10 20 30 40 50 60 70 80 90 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797
1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017
2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237
3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457
4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677
5 1.100 3.300 5.499 7.969 9.899 12.098 14.298 16.498 18.697 20.897
6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117
7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337
8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557
9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3
1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5
2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7
3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0
4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2
5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4
6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7
7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9
8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1
9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414
1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428
2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442
3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456
4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470
5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485
6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499
7 99.6 241.8 384.0 526.3 668.5 810.7 953.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513
8 113.8 256.0 398.3 540.5 682.7 825.0 967.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527
9 128.0 270.2 412.5 554.7 696.9 839.2 981.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column 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.
1C = 33.8F
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 0 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
}.
00-22
04-05
01 GENERAL
Specification drawings....................................... 01- 2 Specifications .................................................... 01- 3 Weight table ...................................................... 01- 9 Fuel, coolant and lubricants .............................. 01-10
HD465-7, HD605-7
01-1
GENERAL
SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
HD465-7
HD605-7
01-2
HD465-7, HD605-7
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model Serial No. Empty Max. load Gross Weight (front) Weight distribution Empty (rear) (front) Gross (rear) Struck Dump body capacity Heaped (2 :1) Performance Max. travel speed Gradeability (sin ) Min. turning radius Dumping angle Overall length Overall width Dimensions Overall height Wheel base Front wheel Tread Rear wheel Ground clearance Model Type No. of cylinders Bore x stroke Piston displacement Engine Rated output Max. torque Fuel consumption (Min.) Stating motor Alternator Battery mm {cc} kW/rpm{HP/rpm} Nm/rpm{kgm/rpm} g/kWh {g/HPh} mm mm 3,080 645 KOMATSU SAA6D170E-3 4-cycle, water-cooled, in-line 6-cylinder, direct injection, with turbocharger and after-cooler 6 170 x 170 23.15 {23,150} 533/2,000 {715/2,000} 3,256/1,400 {332/1,400} 207 {154} 24V, 7.5 kW x 2 units 24V, 50A 12V, 200Ah x 2 units m3 km/h % m mm mm mm mm mm 34.2 70 37 8.5 48 9,355 4,595 4,400 4,300 3,515 kg m3 66,555 (68%) 25 kg kg 22,680 (53%) 31,320 (32%) kg kg kg kg HD465-7 7001 and up 42,800 55,000 97,875 20,120 (47%)
HD465-7, HD605-7
01-3
(10)
GENERAL
SPECIFICATIONS
Machine model
HD465-7
Serial No.
7001 and up
Structure Torque converter Lock- up clutch
3-element, 1-stage, 2-phase Hydraulically actuated, wet-type, multiple-disk clutch
Type Transmission Power train No. of speeds
TORQFLOW planetary gear Fully automatic, electrically-hydraulically actuated, force-feed type pump F7, R1
Type Reduction gear Reduction ratio Differential type
Spiral bevel gear, splash lubrication 3.538 Straight bevel gear, splash lubrication
Type Final drive Reduction ratio Steering system
Planetary gear, splash lubrication 4.737
Type
Fully hydraulic steering system
Front axle Suspension Axle type Rear axle Front axle Suspension method Rear axle
Independent suspension (Mac Pherson type) Full floating Hydropneumatic (Automatic damping force selection type) Hydropneumatic
Front tire Tires Size and No. Rear tire Tire pressure Front and rear tire kPa {kg/cm2}
24.00 35 36PR x 2 24.00 35 36PR x 4 470 {4.75}
Front wheel Service brake Breke system Rear axle
Single dry disc type, Hydraulically controlled 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
(10)
HD465-7, HD605-7
GENERAL
SPECIFICATIONS
Machine model Serial No.
HD465-7 7001 and up
For both steering and work equipment Type Delivery (at engine rated speed 2,000 rpm) Hydraulic pump For charging torque converter Type Delivery (at engine rated speed 2,000 rpm) For brake cooling Type Delivery (at engine rated speed 2,000 rpm) /min Gear pump 456 /min Gear pump 228 /min Gear pump 348
Hydraulic system
Hoist cylinder Type Cylinder No. bore (1st 2nd) x stroke Steering cylinder Type No. bore x stroke Piston type, double acting 2 85 mm x 410 mm 2-stage piston type (only 2nd stage: double-acting) 2 (170 mm 150 mm) x 1,774 mm
HD465-7, HD605-7
01-5
GENERAL
SPECIFICATIONS
Machine model Serial No. Empty Max. load Gross Weight (front) Weight distribution Empty (rear) (front) Gross (rear) Struck Dump body capacity Heaped (2 :1) Performance Max. travel speed Gradeability (sin ) Min. turning radius Dumping angle Overall length Overall width Dimensions Overall height Wheel base Front wheel Tread Rear wheel Ground clearance Model Type No. of cylinders Bore x stroke Piston displacement Engine Rated output Max. torque Fuel consumption (Min.) Stating motor Alternator Battery mm {cc} kW/rpm{HP/rpm} Nm/rpm{kgm/rpm} g/kWh {g/HPh} mm mm m3 km/h % m mm mm mm mm mm kg m3 kg kg kg kg kg kg
HD605-7 7001 and up 45,900 63,000 108,975 21,575 (47%) 24,325 (53%) 34,870 (32%) 74,105 (68%) 29 40 70 37 8.5 48 9,355 4,595 4,400 4,300 3,515 3,080 645 KOMATSU SAA6D170E-3 4-cycle, water-cooled, in-line 6-cylinder, direct injection, with turbocharger and after-cooler 6 170 x 170 23.15 {23,150} 533/2,000 {715/2,000} 3,256/1,400 {332/1,400} 207 {154} 24V, 7.5 kW x 2 units 24V, 50A 12V, 200Ah x 2 units
01-6
(10)
HD465-7, HD605-7
GENERAL
SPECIFICATIONS
Machine model
HD605-7
Serial No.
7001 and up
Structure Torque converter Lock- up clutch
3-element, 1-stage, 2-phase Hydraulically actuated, wet-type, multiple-disk clutch
Type Transmission Power train No. of speeds
TORQFLOW planetary gear Fully automatic, electrically-hydraulically actuated, force-feed type pump F7, R1
Type Reduction gear Reduction ratio Differential type
Spiral bevel gear, splash lubrication 3.538 Straight bevel gear, splash lubrication
Type Final drive Reduction ratio Steering system
Planetary gear, splash lubrication 4.737
Type
Fully hydraulic steering system
Front axle Suspension Axle type Rear axle Front axle Suspension method Rear axle
Independent suspension (Mac Pherson type) Full floating Hydropneumatic (Automatic damping force selection type) Hydropneumatic 24.00 R35 aa x 2 24.00 R35 aa x 4 kPa {kg/cm2} 686 {7.0}
Front tire Tires Size and No. Rear tire Tire pressure Front and rear tire
Front wheel Service brake Breke system Rear axle
Single dry disc type, Hydraulically controlled 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
(10)
GENERAL
SPECIFICATIONS
Machine model Serial No.
HD605-7 7001 and up
For both steering and work equipment Type Delivery (at engine rated speed 2,000 rpm) Hydraulic pump For charging torque converter Type Delivery (at engine rated speed 2,000 rpm) For brake cooling Type Delivery (at engine rated speed 2,000 rpm) /min Gear pump 456 /min Gear pump 228 /min Gear pump 348
Hydraulic system
Hoist cylinder Type Cylinder No. bore (1st 2nd) x stroke Steering cylinder Type No. bore x stroke Piston type, double acting 2 85 mm x 410 mm 2-stage piston type (only 2nd stage: double-acting) 2 (170 mm 150 mm) x 1,774 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 Serial Number Engine assembly Output shaft assembly Radiator assembly Fuel tank Torque converter assembly Transmission assembly Drive shaft assembly (front) Drive shaft assembly (rear) Rear axle assembly HD465-7 7001 and up 2,740 123 304 276 403 1,184 28 62 6,355 822 1,502 646 330 142 460 172 4,698 920 63 44 206 26 20 34 28 33 23 10,730 HD605-7 7001 and up 2,740 123 304 276 403 1,184 28 62 6,355 822 1,502 646 330 142 460 172 4,698 920 63 44 206 26 20 34 28 33 23 13,418
Differential Final drive (one-side) Rear brake (one-side)

Front axle (one-side) Front brake (one-side) Front suspension cylinder Rear suspension cylinder Frame Cab (Platform) Operator's seat Steering cylinder Hoist cylinder Demand valve Steering valve Hoist valve Hydraulic pump (SAR(3)100+100) Hydraulic pump (SAR(3)80+80) Hydraulic pump (SAR(3)100+(1)25) Dump body
HD465-7, HD605-7
01-9
(10)
GENERAL
FUEL, COOLANT AND LUBRICANTS
01-10
(10)
HD465-7, HD605-7
GENERAL
Engine Oil Pan Specified capacity ( ) Refill capacity ( ) 67 57
Transmission Case 285 190
Steering, Hoist Oil Tank 180 122
Front Suspension 17 each for right and left
Rear Suspension 11.3 each for right and left
Differential Case 95 95
Final drive case Specified oil level ( ) Refill capacity ( ) 32 each for right and left 21 each for right and left
Fuel tank 780
Cooling system 154
Fuel and oil Select fuel and oil according to the above table. Coolant Since Komatsu genuine Supercoolant (AF-ACL) is added to the cooling water, the latter does not need to be replaced while the atmospheric temperature is above 10C. If the atmospheric temperature drops below 10C, adjust the concentration of AF-ACL according to the operation and meintenance manual. a The specified capacity means the total amount of oil including oil for components and oil in piping. The refill capacity means the amount of oil needed to refill the system during normal inspection and maintenance. a When starting the engine in an atmospheric temperature of lower than 0C, 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 temperature goes up to 10C or above during the day.
HD465-7, HD605-7
01-11
(10)
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler ....... 10- 3 Brake oil cooler............................................ 10- 4 Power train skeleton.................................... 10- 5 Output shaft................................................. 10- 6 Drive shaft .................................................. 10-7-1 Torque converter and transmission hydraulic piping......................................................... 10- 8 Torque converter ......................................... 10-10 Transmission ............................................... 10-18 Transmission valve...................................... 10-27 ECMV ......................................................... 10-28 Axle ............................................................. 10-38 Differential ................................................... 10-42 Final drive.................................................... 10-44 Wheels ........................................................ 10-46 Suspension.................................................. 10-48 Suspension cylinder .................................... 10-50 Rear axle support ........................................ 10-56 Steering column........................................... 10-58 Steering linkage........................................... 10-59 Brake piping ................................................ 10-62 Brake valve.................................................. 10-64 Emergency brake valve............................... 10-67 Relay valve.................................................. 10-68 Front brake off valve.................................... 10-69 Accumulator charge valve ........................... 10-71 Accumulator ................................................ 10-75 Slack adjuster.............................................. 10-76 Brake ........................................................... 10-78 Proportional reducing valve......................... 10-83 Parking brake solenoid valve ...................... 10-84 Steering and hoist hydraulic piping.............. 10-86 Steering and hoist hydraulic system diagram...................................................... 10-88 Dump body control ...................................... 10-90 HYdraulic tank ............................................. 10-91 Steering control valve .................................. 10-92 Crossover relief valve .................................. 10-96 Steering cylinder .......................................... 10-97 Demand valve.............................................. 10-98 Hoist valve ................................................. 10-102 EPC valve.................................................. 10-108 Hoist cylinder ............................................. 10-109 Hydraulic pump.......................................... 10-110 Air conditioner............................................ 10-114 Machine monitor system............................ 10-119 Engine control system ............................... 10-134 Automatic shift control system ................... 10-136 Payload meter (card type)...................... 10-151 Automatic emergency steering system...... 10-184 Automatic suspension system ................... 10-188 Retarder control system ............................ 10-192 Sensors, switches...................................... 10-204 Dump lever ................................................ 10-212 [Related to VHMS controller] VHMS controller ........................................ 10-216 BLOW-BY pressure sensor ....................... 10-216 Engine oil temperature sensor................... 10-217 Exhaust temperature sensor/amp ............. 10-218 Ambient temperature sensor...................... 10-218 Communications (orborbcomm) controller/antenna.................................... 10-219 Payload meter (Having VHMS) ................. 10-220
For details of VHMS, see TESTING AND ADJUSTING.
HD465-7, HD605-7
10-1
(10)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER
1. Pick-up for radiator coolant level sensor 2. Upper tank 3. Lower tank 4. Core 5. Work equipment oil cooler 6. After cooler 7. Fuel cooler A : Coolant inlet port B : Coolant outlet port
Specifications Radiator Core type: CF4-5 Total radiation surface: 130.6 m2 Work equipment oil cooler Core type: CF40-1 Radiation surface: 2.90 m2 Fuel cooler Core type: FC1-3 Heat radiation area: 6.75 m2
HD465-7, HD605-7
10-3
(10)
BRAKE OIL COOLER
BRAKE OIL COOLER
1. Cooler element A : Oil inlet B : Oil outlet C : Coolant inlet D : Coolant outlet
Oil cooler specifications Element type : Multiple plate Radiation surface: 8.13 m2 Pressure resistance (oil side): 2.9 MPa {30 kg/cm2}
10-4
(10)
HD465-7, HD605-7
POWER TRAIN SKELETON
POWER TRAIN SKELETON

1. 2. 3. 4. 5. Engine Output shaft Front drive shaft Brake cooling pump (SAR(3)100+100) Torque converter transmission charge pump and brake cooling brake control pump (SAR(3)100+25) PTO Torque converter Transmission Rear drive shaft Differential gear Drive shaft Brake Tire Final drive Parking brake Steering, hoist and hoist control pump (SAR(3)80+80+(1)6)
6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
HD465-7, HD605-7
10-5
OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion 2. Outer body 3. Flange 4. Shaft 5. Coupling 6. Inner body 7. Cover
Function The output shaft is installed to the engine flywheel, and absorbs the twisting vibration caused by changes in the engine torque.
10-6
HD465-7, HD605-7
OUTPUT SHAFT
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.045 0.005 0.005 0.040 0.039 0.016 0.050 0.002 Repair limit 0 0.1 Backlash limit 0.4 Standard backlash (Dimension at smallest width: L) 81 67 No cracks Clearance limit
Remedy
Clearance between flywheel and bearing 100
Shaft 0 0.015 0.010 0.040 +0.006 0.024 +0.025 +0.003 Standard size
Hole 0.010 0.045 0 0.015 0.008 0.033 +0.005 0.025
0.02 0.10 0.06 0.013 Replace
2 3 4
Clearance between shaft and bearing Clearance between bearing and cover Clearance between bearing and shaft Wear of oil seal contact surface of coupling
55 150 85
110 Standard backlash
Repair or replace
Backlash at spline 0.080 0.231 Original dimension: Lo Defomation of rubber cushion
Replace
90 75
External
HD465-7, HD605-7
10-7
(10)
DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 2. Rear drive shaft
Outline The power from the engine is transmitted through the output shaft, the front drive shaft (1) and the transmission, to the rear drive shaft (2).
10-7-1
(6)
HD465-7, HD605-7
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
10-8
HD465-7, HD605-7
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
TORQUE CONVERTER
TORQUE CONVERTER
1. PTO Gear (Number of teeth : 91) A : Main oil pressure detection port B : Torque converter oil inlet C : Torque converter oil inlet pressure detection port D : Torque converter oil outlet E : To transmission control valve F : To lock-up clutch G: Torque converter oil outlet pressure detection port H : To transmission lubrication
Specification Type : 3-element, 1-stage, 2-phase With modulation With lock-up clutch Lock-up clutch : Wet type double plate clutch Hydraulic control (with modulation mechanism) Stall torque ratio: 2.32
10-10
(10)
HD465-7, HD605-7
TORQUE CONVERTER
1. 2. 3. 4. 5. 6. 7. 8. 9.
Coupling Input shaft (Number of teeth : 108) Front housing Drive case Turbine Race Torque converter valve Pump Rear housing
10. 11. 12. 13. 14. 15. 16.
Stator shaft One-way clutch Stator Disc Piston Clutch housing Retainer
HD465-7, HD605-7
10-11
TORQUE CONVERTER
10-12
HD465-7, HD605-7
TORQUE CONVERTER
Unit: mm
No.
1
Check item
Standard size Coupling oil seal sliding portion outside diameter Input shaft seal ring sliding portion inside diameter Pump housing seal ring sliding portion inside diameter Input shaft seal ring sliding portion inside diameter Stator shaft seal ring wear Width Thickness 110 35 135 75 3.95 5.1 127.844
Criteria
Tolerance 0 0.087 +0.025 0 +0.040 0 +0.030 0 0 0.1 0.1 0.013 Repair limit 109.8 35.1 135.5 75.1 3.55 4.59 127.874
Remedy
2 3 4
Correction by chrome plating or replacement
Outer race one-way clutch transmission face inside diameter Inner race one-way clutch transmission face outside diameter Bushing sliding portion inside diameter Bushing sliding portion thickness Clutch disc thickness
108.883 108.96 5 5.4
0.013 +0.040 +0.018 0 0.1 0.1 Tolerance Standard clearance 0.5 0.797 0.11 0.272
108.853 109.04 4.5 4.8 Clearance limit
8 9 10
Replace
Standard size 11 Clearance between clutch housing and piston (outside) 420 12 Clearance between clutch housing and piston (inside) 295 Shaft 0.5 0.7 0.110 0.191 Hole +0.097 0 +0.081 0
0.88 0.30
HD465-7, HD605-7
10-13
TORQUE CONVERTER
POWER TRAIN
When the lock-up clutch is [RELEASED] When the lock-up clutch is [IN]
When the lock-up clutch is [RELEASED], the drive case (1) is separated from the turbine (2) and the torque converter functions as a normal torque converter. The power generated with the engine is transmitted to the coupling (3), the input shaft (4) and the clutch housing (5) through the drive shaft and the damper and rotates the drive case (1) and the pump (6) as one part. Power of the pump (6) rotates the turbine (2) using oil as the medium and is transmitted from the turbine (2) to the transmission input shaft (7).
When the lock-up clutch is [IN], the drive case (1) and the turbine (2) are connected and integrated, and the stator (8) rotates with the pump (6) and the turbine (2). The power generated with the engine is transmitted to the coupling (3), the input shaft (4) and the clutch housing (5) through the propeller shaft from the damper and rotates the drive case (5) and the pump (6) as one part. Since the drive case (1) and the turbine (2) were connected, the power is transmitted directly to the transmission input shaft (7) from the turbine (2) not using oil as the medium.
10-14
(9)
HD465-7, HD605-7
TORQUE CONVERTER
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 cooling from the outlet port B and is used for lubricating the transmission.
HD465-7, HD605-7
10-15
(9)
TORQUE CONVERTER
TORQUE CONVERTER VALVE
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.035 0.061 0.035 0.061 Repair limit Installed load 1213.2 N {123.8 kg} 331.2 N {33.8 kg} 32.0 N {3.3 kg} Free length 114.5 132.9 25.2 Installed load 1153.8 N {117.6 kg} 315.0 N {32.1 kg} 30.8 N {3.1 kg} Clearance limit
Remedy
Clearance between torque converter spool and body 32
Shaft 0.035 0.045 0.035 0.045 Standard size
Hole +0.016 0 +0.016 0
0.081 0.081 Replace
Clearance between main relief spoon and body
32
Main relief valve spring
Free length 118
Installed length 94.5 93.5 17
4 5
Torque converter relief valve spring Poppet spring (touque converter relief, main relief)
137 26
10-16
(10)
HD465-7, HD605-7
TRANSMISSION
TRANSMISSION
10-18
HD465-7, HD605-7
TRANSMISSION
1. Input shaft 2. Transmission valve 3. Coupling 4. Strainer 5. Drain valve
A : Speed sensor (for input shaft) B : Speed sensor (for intermediate shaft) C : Speed sensor (for output shaft) D : Lubricating oil pressure detection port 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
TRANSMISSION
10-20
HD465-7, HD605-7
TRANSMISSION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.
Input shaft No. 1 sun gear (Number of teeth : 34) No. 1 clutch hub No. 1 clutch (High) No. 1 planetary pinion (Number of teeth : 32) No. 1 planetary carrier No. 2 clutch hub No. 2 clutch (Low) No. 1 ring gear (Number of teeth : 98) No. 2 clutch housing No. 3 clutch housing No. 3 clutch drum No. 3 clutch (4th) No. 3 clutch hub No. 4 planetary pinion (Number of teeth : 21) No. 4 clutch (3rd) No. 4 ring gear (Number of teeth : 93) No. 4 sun gear (Number of teeth : 51) No. 5 clutch (R) No. 5 planetary pinion (Number of teeth : 21) No. 5 sun gear (Number of teeth : 41) No. 5 ring gear (Number of teeth : 93) No. 6 clutch (2nd) No. 6 ring gear (Number of teeth : 105) No. 6 planetary pinion (Number of teeth : 30) No. 6 sun gear (Number of teeth : 45) No. 6, 7 planetary carrier No. 7 clutch (1st) No. 7 ring gear (Number of teeth : 104) Output shaft No. 7 planetary pinion (Number of teeth : 38) No. 7 clutch piston No. 6 clutch piston Intermediate shaft (No. 7 sun gear : Number of teeth 28) No. 5 clutch piston No. 5 planetary pinion (Number of teeth : 21) No. 4, 5 planetary carrier No. 3 clutch piston No. 2 clutch piston No. 1 clutch piston No. 4 clutch piston
HD465-7, HD605-7
10-21
TRANSMISSION
10-22
HD465-7, HD605-7
TRANSMISSION
Unit: mm
No.
Check item
Standard size
Criteria
Repair limit Installed load 74.5 N {7.6 kg} 49.1 N {5.0 kg} 141.2 N {14.4 kg} 113.8 N {11.6 kg} 179.5 N {18.3 kg} Tolerance 0.22 0.30 0.26 0.26 0.30 0.28 0.26 0.10 0.10 0.10 0.10 0.01 0.03 0.10 0.01 0.03 0.10 0.01 0.03 0.12 Free length 39.5 48.9 85.5 63.9 63.9 Installed load 63.7 N {6.5 kg} 42.2 N {4.3 kg} 119.6 N {12.2 kg} 97.1 N {9.9 kg} 153.0 N {15.6 kg} Repair limit 25.8 42 32.3 33.9 43.7
Remedy
No. 1 clutch spring
Free length 42.0
Installed length 32.0 49.1 75.0 57.85 52.0
2 3 4 5
No. 4 clutch spring No. 5 clutch spring No. 6 clutch spring No. 7 clutch spring
52.0 91.0 68.0 68.0
Standard size 6 Total thickness of 3 discs and 2 plates for No. 1 clutch Total thickness of 5 discs and 4 plates for No. 2 clutch Total thickness of 4 discs and 3 plates for No. 3 clutch Total thickness of 4 discs and 3 plates for No. 4 clutch Total thickness of 5 discs and 4 plates for No. 5 clutch Total thickness of 4 discs and 4 plates for No. 6 clutch Total thickness of 4 discs and 3 plates for No. 7 clutch No. 1,4,5,6,7 No. 2,3 No. 1,6,7 14 Thickness of 1 plate No. 2,3,4,5 Width Thickness Width Thickness 27.8 45.0 35.0 36.6 47 44.8 39.0 5.4 5.0 5.8 5.0 2.56 1.7 3.0 3.1 4.0 4.6
7 8 9 10 11 12
Replace 42.1 36.3 4.8 4.4 5.6 4.8 2.30 1.55 2.70 2.95 3.6 4.45
13
Thickness of 1 disc
15
Wear of transmission input shaft seal ring (small)
16
Wear of transmission input shaft seal ring (large)
17
Wear of No. 1 car- Width rier, No. 3 clutch hub and No. 4 sun Thickness gear seal rings
HD465-7, HD605-7
10-23
TRANSMISSION
Unit: mm
No.
Check item
Standard size Width 4.0 Thickness Width Thickness Width Thickness Width Thickness Width Thickness 5.1 4.0 6.3 4.0 4.0 3.95 5.25 4.0 4.0
Criteria
Tolerance 0.01 0.03 0.12 0.01 0.04 0.15 0.01 0.04 0.15 0 0.1 0.1 0.01 0.04 0.15 0.13 0.36 0.16 0.41 Repair limit 3.6 4.85 3.6 6.15 3.6 3.85 3.56 4.73 3.6 3.85
Remedy
18
Wear of No. 2 and 3 clutch collar seal rings
19
Wear of No. 4 and 5 carrier seal rings
20
21
22
23 24 25 26 27 28 29 30 31 32 33 34
Backlash between No. 1 sun gear and planetary gear Backlash between No. 1 planetary gear and ring gear Backlash between No. 4 sun gear and planetary gear Backlash between No. 4 planetary gear and ring gear Backlash between No. 5 sun gear and planetary gear Backlash between No. 5 planetary gear and planetary gear Backlash between No. 5 planetary gear and ring gear Backlash between No. 6 sun gear and planetary gear Backlash between No. 6 planetary gear and ring gear Backlash between No. 7 sun gear and planetary gear Backlash between No. 7 planetary gear and ring gear Disc inner teeth deformation Standard size
Replace 0.14 0.36 0.15 0.39 0.14 0.36 0.13 0.34 0.15 0.39 0.16 0.41 0.16 0.41 0.13 0.36 0.17 0.44 Repair limit : 0.3 Tolerance 0.1 0.1 Repair limit 1.6 2.4
35
Thrust washer thickness (No. 1, 4 and 5 planetary gears) Thrust washer thickness (No. 6 and 7 planetary gears)
2 3
36
10-24
HD465-7, HD605-7
TRANSMISSION
Unit: mm
No.
Check item
Location No. 1 gear train No. 4 gear train
Criteria
Standard clearance 0.30 0.80 0.30 0.80 0.30 0.80 0.30 0.80 0.30 0.80 Wear 0.05 max. Clearance limit 1.5 1.5 1.5 1.5 1.5
Remedy
37
Planetary gear side clearance No. 5 gear train No. 6 gear train No. 7 gear train Standard size
Replace the thrust washer or the carrier
38
Stepped-type wear of seal ring counter face
Standard size
Replace Repair limit 119.8 Tolerance Shaft 0.5 0.7 0.135 0.232 0.5 0.7 0.110 0.191 0.5 0.7 0.5 0.7 0.125 0.214 0.125 0.214 0.125 0.214 Hole +0.097 0 +0.097 0 +0.081 0 +0.081 0 +0.063 0 +0.089 0 +0.089 0 +0.089 0 +0.089 0 Standard clearance 0.5 0.797 0.135 0.329 0.5 0.781 0.110 0.272 0.5 0.763 0.5 0.789 0.125 0.303 0.125 0.303 0.125 0.303 Clearance limit 0.88 0.36 0.86 0.30 0.84 0.87 0.33 0.33 0.33 When any damage like seized streak is found on any surface, if corrected and the allowable clearance is maintained, it can be used. Replace it if damaged remarkably 39 Output shaft oil seal contact surface
120 Standard size 430 405 275 255 175 430 395 380 375
Clutch No. No. 1 Outside Inside No. 2,3 Outside Clearance between cylinder and piston Middle Inside No. 4,5,6,7 Outside No. 4 Inside No. 5,7 Inside No. 6 Inside
40
HD465-7, HD605-7
10-25
TRANSMISSION
Outline The transmission consists of an F7 R1 planetary gear type transmission with a control valve. The transmission and torque converter are connected at the transmission input shaft. Gear shifting is carried out automatically by the automatic transmission according to changes in engine speed. Gear Shifting Function The inside of the transmission consists of 7 clutch packs and 5 sets of planetary gears. These are divided into the front group and rear group. One clutch pack in the front group and one clutch pack in the rear group are actuated simultaneously by oil pressure sent from the transmission valve to give the speed range and reduction ratio.
Group Front group
Clutch pack No. 1 clutch (High) No. 2 clutch (Low) No. 3 clutch (4th) No. 4 clutch (3rd)
Planetary gear
No. 1 planetary gear
No. 4 planetary gear No. 5 planetary gear No. 6 planetary gear No. 7 planetary gear
Rear group
No. 5 clutch (R) No. 6 clutch (2nd) No. 7 clutch (1st)
Speed range F1 F2 F3 F4 F5 F6 F7 R
Clutches engaged No. 2 No. 7 (Low 1st) No. 2 No. 6 (Low 2nd) No. 1 No. 6 (High 2nd) No. 2 No. 4 (Low 3rd) No. 1 No. 4 (High 3rd) No. 2 No. 3 (Low 4th) No. 1 No. 3 (High 4th) No. 2 No. 5 (Low R)
Reduction ration 4.714 3.333 2.475 1.825 1.355 1.000 0.742 3.969
10-26
(10)
HD465-7, HD605-7
TRANSMISSION VALVE
TRANSMISSION VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
ECMV (for high clutch) ECMV (for lockup clutch) ECMV (for low clutch) ECMV (for 4th clutch) ECMV (for 3rd clutch) ECMV (for R clutch) ECMV (for 2nd clutch) ECMV (for 1st clutch) Valve oil filter Seat
A : High clutch pressure detection port B : Lockup clutch pressure detection port C : Low clutch pressure detection port D : 4th clutch pressure detection port E : 3rd clutch pressure detection port F : R clutch pressure detection port G: 2nd clutch pressure detection port H : 1st clutch pressure detection port
ECMV Clutch Operation Table

ECMV Gear range F1 F2 F3 F4 F5 F6 F7 N R1 R 1st 2nd 3rd 4th Low High
HD465-7, HD605-7
10-27
(9)
ECMV
ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve (FOR HIGH, LOCKUP, REV AND 1ST CLUTCHES)
1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve (*1) 7. Nameplate (*2) A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port
*1: The spool of pressure control valve is difference between the clutch for High, Rev and 1st clutches, and the clutch for lockup. *2: The character on nameplate is different between nameplates for high, Rev and 1st clutches and that for lockup clutch.
Applicable clutch High, Rev, 1st Lockup Character on nameplate A******* E*******
10-28
(9)
HD465-7, HD605-7
ECMV
ECMV FOR LOCKUP CLUTCH

Outline This valve is used for setting oil pressure of the lockup clutch to the set pressure, and for switching lockup clutch. Since the modulation actuates as shown below, the valve enables to engage the lockup clutch smoothly and to reduce shocks at the time of gearshift. Also, the valve prevents the power train from causing peak torque. This improves operator comfort and makes the power train more durable.
WHEN SWITCHING LOCKUP CLUTCH (Lockup clutch OFF to ON)
Operation When the torque converter is operating without lockup.
WHEN SHIFTING GEAR (At direct driving)
When the torque converter is operating without lockup, no current is flowing to the proportional solenoid (1). The pressure control valve (3) drains oil from the clutch port A through the drain port T, and the lockup clutch is [RELEASED]. Since oil pressure force does not work to the pressure detection valve (4), the fill switch (5) is turned "OFF".
HD465-7, HD605-7
10-29
(10)
ECMV
WHEN THE TORQUE CONVERTER IS OPERATING WITH LOCKUP (Torque converter operation with lockup : Lockup operation) At filling time
At pressure adjusting time
Electric signal commands to flow the current to the proportional solenoid (1) in case of lockup operation. Then oil pressure force balancing with solenoid force works in Chamber B and pushes the pressure control valve (3) to the left. Then the pump port P and the clutch port A open, the valve starts filling the clutch with oil, and when the clutch is filled with oil, the fill switch (5) is turned "ON".
When the current is supplied to the proportional solenoid (1), the solenoid generates thrusting force in proportion to the current. The solenoid thrust force balances with the sum of the clutch port thrust force by oil pressure, and bounce force of the pressure control valve spring (2). Then the pressure is adjusted. To reduce gear shift shock, the oil pressure of 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
(9)
HD465-7, HD605-7
ECMV
ECMV FOR SPEED RANGE CLUTCH

Outline of ECMV The ECMV consists of a pressure regulator valve and a fill switch. Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil pressure. Fill switch Detects that the clutch is filled with oil. It has the functions below. 1. When the clutch is filled with oil, a signal (the fill signal) is sent to the controller to notify that filling is finished. 2. While oil pressure is being applied to the clutch, a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. ECMV and proportional solenoid One proportional solenoid is installed for one ECMV. After receiving the command current from the controller, it produces thrust shown in the graph below. By making the proportional solenoid-produced thrust act on the pressure control valve spool, it produces an oil pressure shown in the graph below. By controlling the amount of command current, the thrust is changed to operate the pressure control valve, controlling the oil flow and oil pressure. Current-Propulsion force characteristics of propotional solenoid
Propulsion force-Hydraulic pressure characteristics of proportional solenoid
A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).
ECMV and fill switch One fill switch is installed for one ECMV. If the clutch finishes filling, the fill switch is turned "ON" by the pressure of the clutch. By this signal, the oil pressure starts build-up.
HD465-7, HD605-7
10-31
(9)
ECMV
ECMV operation The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. The relationship between the proportional command current for the ECMV, clutch input pressure and output signal of the fill switch is shown in the graph below.
Before shifting gear (when drained) (A range in chart)
When no current is supplied to the proportional solenoid (1), the pressure control valve (3) is draining oil from the clutch port A through the drain port T. Since no oil pressure works to the pressure detection valve (4), the fill switch (5) is "OFF".
A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).
10-32
(9)
HD465-7, HD605-7
ECMV
Filling (B range in chart)
Pressure regulation (C range in chart)
When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil, an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. Then, the pump port P and the clutch port A open, the valve starts filling the clutch with oil, and when the clutch fills with oil, the fill switch (5) is turned "ON".
When a current is supplied to the proportional solenoid (1), the solenoid generates a thrust in proportion to the current. The solenoid thrust, and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure.
HD465-7, HD605-7
10-33
(9)
ECMV
(FOR LOW, 4TH, 3RD AND 2ND CLUTCHES WITH FLOW DETECTION VALVE)
1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve 7. Nameplate (*1)
*1: Applicable clutch Low, 4th, 3rd, 2nd Character on nameplate D*******
A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port
10-34
(9)
HD465-7, HD605-7
ECMV
ECMV FOR SPEED RANGE CLUTCH

Outline of ECMV The ECMV consists of a pressure regulator valve and a fill switch. Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil pressure. Fill switch Detects that the clutch is filled with oil. It has the functions below. 1. When the clutch is filled with oil, a signal (the fill signal) is sent to the controller to notify that filling is finished. 2. While oil pressure is being applied to the clutch, a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. ECMV and proportional solenoid One proportional solenoid is installed for one ECMV. After receiving the command current from the controller, it produces thrust shown in the graph below. By making the proportional solenoid-produced thrust act on the pressure control valve spool, it produces an oil pressure shown in the graph below. By controlling the amount of command current, the thrust is changed to operate the pressure control valve, controlling the oil flow and oil pressure. Current-Propulsion force characteristics of propotional solenoid
Propulsion force-Hydraulic pressure characteristics of proportional solenoid
A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).
ECMV and fill switch One fill switch is installed for one ECMV. If the clutch finishes filling, the fill switch is turned "ON" by the pressure of the clutch. By this signal, the oil pressure starts build-up.
HD465-7, HD605-7
10-35
(9)
ECMV
ECMV operation The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. The relationship between the proportional command current for the ECMV, clutch input pressure and output signal of the fill switch is shown in the graph below.
Before shifting gear (when drained) (A range in chart)
A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).
When no current is supplied to the proportional solenoid (1), the pressure control valve (3) is draining oil from the clutch port A through the drain port T. Since no oil pressure works to the flow detection valve (4), the fill switch (5) is "OFF".
10-36
(9)
HD465-7, HD605-7
ECMV
Filling (B range in chart)
Pressure regulation (C range in chart)
When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil, an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. Then, the valve 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 differential 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 disappears 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 pressure force, and the fill switch (5) is turned "ON".
When a current is supplied to the proportional solenoid (1), the solenoid generates a thrust in proportion to the current. The solenoid thrust, and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure.
HD465-7, HD605-7
10-37
(9)
AXLE
AXLE
FRONT
1. Wheel hub
Unit: mm
No.
2
Check item
Standard size Wear of oil seal sliding surface 280
Criteria
Tolerance 0 0.130 Repair limit
Remedy
Repair or replace
10-38
(10)
HD465-7, HD605-7
AXLE
REAR
1. Differential 2. Axle housing 3. Brake 4. Final drive
Specifications Reduction ratio Differential: 3.538 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
DIFFERENTIAL
DIFFERENTIAL
1. Coupling 2. Cross shaft 3. Bevel gear (No. of teeth: 46) 4. Side gear (No. of teeth: 24) 5. Pinion gear (No. of teeth: 17) 6. Bevel pinion (No. of teeth: 13)
Specifications Type: Spiral bevel gear, splash-type lubrication Reduction ratio: 3.538 Differential: Straight bevel gear, splash-type lubrication Oil: EO30-CD (95 liters)
10-42
HD465-7, HD605-7
DIFFERENTIAL
Unit: mm
No.
7
Check item
Standard size Wear of oil seal contact surface of coupling Thickness of side gear thrust washer Backlash between bevel gear and pinion 150 6
Criteria
Tolerance 0 0.100 0 0.050 0.41 0.56 Repair limit 5.5
Remedy
Repair or replace
8 9
Replace Adjust
HD465-7, HD605-7
10-43
FINAL DRIVE
FINAL DRIVE
1. Sun gear (No. of teeth: 19) 2. Planet gear (No. of teeth: 31) 3. Planet gear shaft 4. Ring gear (No. of teeth: 87) 5. Inner hub 6. Wheel hub 7. Drive shaft
Specification Type: Planetary gear, splash-type lubrication Reduction ratio: 4.737 Oil: EO30-CD (32 liters each side)
10-44
HD465-7, HD605-7
FINAL DRIVE
Unit: mm
No.
8
Check item
Standard backlash Backlash between planet gear and sun gear Backlash between planet gear and ring gear Curvature of drive shaft Standard size 0.22 0.67 0.28 0.77
Criteria
Repair limit 0.8 1.0 Repair limit: 1.5 TIR Tolerance 0.1 Repair limit
Remedy
Replace
9 10
Repair or replace
11
Thickness of spacer 51.5 50
Replace
HD465-7, HD605-7
10-45
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
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 chassis, and absorbs the shock from uneven road surfaces to provide a comfortable ride for the operator. At the same time, it maintains the stability of the machine by ensuring that all four wheels are always in contact with the ground surface. In this way, it allows the machine to demonstrate its full performance in items such as acceleration, braking, and turning, even when traveling at high speed. Hydropneumatic cylinders are used for the suspension cylinders to reduce the shock. With
hydropneumatic cylinders, the suspension cylinder is charged (sealed) with oil and nitrogen gas. This acts as a shock absorber (spring and damper) by contracting and expanding the nitrogen gas and oil to absorb the load from the road surface. In addition to these functions, the front suspension employs an automatic suspension system. In this system, the force of the suspension is automatically changed by selecting the dumping force to match the travel conditions and load conditions. This further increases the stability and riding comfort of the machine. HD465-7, HD605-7
10-48
(10)
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 stability of the machine.
2. Rear suspension The differential housing is supported by the frame and two radius rods at the bottom, and at the top by two inverted-V-shaped rods and two suspension cylinders. It is connected to these at both ends by spherical bearings. It transmits the load and motive force through the top and bottom rods. The inverted-V-shaped rods at the top also function to maintain the center of the machine (axle). Employment of the inverted-V-shaped link improves the rolling steering characteristics.
HD465-7, HD605-7
10-49
(6)
SUSPENSION CYLINDER
SUSPENSION CYLINDER
FRONT
1. 2. 3. 4.
Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) 5. Air bleeding valve 6. Tube
7. 8. 9. 10.
Air cylinder Valve assembly Damping force selector valve Damping force selector valve lever
A : Port B : Port
10-50
(10)
HD465-7, HD605-7
SUSPENSION CYLINDER
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.043 0.346 0.403 0.646 0.05 0.375 Clearance limit
Remedy
11
Clearance between piston rod and bushing 160
Shaft 0.043 0.106 0.043 0.106 0.05 0.26
Hole +0.240 0 +0.540 +0.360 +0.115 0
Replace bushing 0.4 0.7 0.8 Repair limit Replace bushing Replace wear ring
12 13
Clearance between piston rod and bushing Clearance between cylinder and wear ring
160 200
14
Elasticity of leaf spring
Max. 0.3 mm
Replace Measuring method: Measure protrusion and elongation of stopper. All the conditions below must be fulfilled. Elongation : Max. 5 mm Protrusion: Max. 2 mm No cracks
15
Deformation of stopper
HD465-7, HD605-7
10-51
(10)
SUSPENSION CYLINDER
Structure and operation The suspension cylinder acts as a shock absorber and spring. The inside of the cylinder is divided into gas chamber A which is charged with nitrogen gas, and oil chamber B which is filled with oil. Oil chamber B and oil chamber C are conmected by tube (6) and valve body (8). a Nitrogen gas When the machine is traveling, the wheels 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 throttled by orifices in four places to generate a damping force. ii) Action when extending When the external force from the road surface gets weak, the pressure of the nitrogen gas extends the rod, and the oil in oil chamber C passes through tube (6) and valve (8) and flows to oil chamber B. The oil inside the valve flows from direction X and passes through two orifices from orifice plate (8a) to generate a damping force.
10-52
(10)
HD465-7, HD605-7
SUSPENSION CYLINDER
c. Variable shaft mechanism In the valve body, bypass circuit D is provided before and after orifice plate (8a), so the oil flow is divided into oil flowing through orifice plate (8a) and oil flowing through the bypass circuit D. The oil flowing through bypass circuit D passes through a shaft with orifices at two places on the inside circumference, and flows to oil chamber C or oil chamber B according to whether it is retracting or extending. The shaft is connected to an air cylinder driven by a signal from the retarder controller, and the size of the orifices automatically changes according to the condition of the machine. The damping force is set at three levels (MEDIUM, HARD, SOFT) according to the size of the orifices through which the oil is passing.
HD465-7, HD605-7
10-53
(6)
SUSPENSION CYLINDER
REAR
1. 2. 3. 4. 5.
Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) Ball
10-54
(10)
HD465-7, HD605-7
SUSPENSION CYLINDER
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.043 0.352 0.043 0.352 0.05 0.375 Clearance limit
Remedy
Shaft 0.043 0.106 0.043 0.106 0.050 0.260
Hole +0.246 0 +0.246 0 +0.115 0.008
0.4 Replace 0.4 0.8
7 8
Clearance between piston rod and bushing Clearance between cylinder and wear ring
180 220
Structure and operation The suspension cylinder has the function of both a shock absorber and spring. When a fixed amount of oil is sent from oil chamber (6) through orifices (4) and (5) to cavity (2), the oil is throttled by the orifices and a shock-absorbing effect is obtained. a) Retracting action When the machine is traveling and it hits a bump or object on the road, the wheels are pushed up, and the cylinder rod is pushed inside the cylinder. When this happens, the nitrogen gas inside chamber (7) is compressed, the oil in chamber (6) is sent through both orifices (4) and (5) to cavity (2), and cavity (2) is filled more quickly than when extending. b) Extending action When the machine has passed any bump or object on the road surface, the cylinder rod is pushed up by the weight of the wheels and axle and the pressure of the nitrogen inside chamber (7). As a result, the amount of oil in cavity (2) is reduced, and pressure is applied to the oil remaining in cavity (2). 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. In this way, the amount of oil returning to chamber (6) is restricted to provide a shock absorbing effect.
1. Valve (for bleeding and mounting pressure sensor) 2. Cavity 3. Check ball 4. Orifice 5. Orifice 6. Oil chamber
7. 8. 9. 10.
Nitrogen gas chamber Cylinder rod Cylinder Feed valve
a : When extending b : When retracting
HD465-7, HD605-7
10-55
(10)
REAR AXLE SUPPORT
REAR AXLE SUPPORT
1. Rod 2. Rod 3. Axle 4. Suspension cylinder
10-56
(6)
HD465-7, HD605-7
REAR AXLE SUPPORT
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.030 0.122 0.110 0.180 0.030 0.076 +0.046 0 0.030 0.122 0.110 0.180 Clearance limit
Remedy
Clearance between rod mounting pin and bushing 70
Shaft 0.030 0.076
Hole +0.046 0
0.3 0.5 Replace
Clearance between inner and outer bushing Clearance between suspension cylinder mounting pin and frame or axle Clearance between inner and outer bushing
100
70
0.3
100
0.5
HD465-7, HD605-7
10-57
(10)
STEERING COLUMN
STEERING COLUMN
1. Steering shaft 2. Steering column 3. Lock lever 4. Yoke 5. Joint shaft 6. Steering valve
10-58
(6)
HD465-7, HD605-7
STEERING LINKAGE
STEERING LINKAGE
1. Center lever 2. Tie rod 3. Arm (A-frame) 4. Knuckle arm
HD465-7, HD605-7
10-59
(6)
STEERING LINKAGE
10-60
(6)
HD465-7, HD605-7
STEERING LINKAGE
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.150 0.300 0 0.035 0.025 0.064 +0.054 0 +0.069 +0.030 0 0.089 0.055 0.133 0.120 0.250 0.025 0.064 +0.069 +0.030 0.055 0.133 0.120 0.250 0.030 0.076 +0.076 +0.030 0.060 0.152 0.110 0.180 0.030 0.076 0.030 0.076 +0.091 +0.045 +0.197 +0.137 0.075 0.167 0.167 0.273 0.120 0.250 0.025 0.064 0.030 0.076 +0.069 +0.030 +0.046 0 0.055 0.133 0.030 0.122 Clearance limit
Remedy
Clearance between inner and outer for knuckle arm bushing 165
Shaft
Hole
0.7 0.3
Clearance between bushing and pin Clearance between steering cylinder mounting pin and bushing Clearance between inner and outer bushing Clearance between tie rod mounting pin and bushing Clearance between inner and outer bushing Clearance between arm mounting pin and bushing Clearance between inner and outer bushing Clearance between arm mounting pin and bushing Clearance between center lever mounting pin and bushing Clearance between inner and outer bushing Clearance between tie rod mounting pin and bushing Clearance between suspension cylinder mounting pin and bushing
85
45
0.3
8 9 10 11 12 13
80 40 110 55 100 70
0.4 0.3 0.4 Replace 0.3 0.5 0.3
14
55
1.0
15 16
80 40
0.4 0.3
17
60
0.3
HD465-7, HD605-7
10-61
(10)
BRAKE PIPING
BRAKE PIPING
HD465-7 Serial No.: 7001 7265 HD605-7 Serial No.: 7001 7112
10-62
(12)
HD465-7, HD605-7
BRAKE PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder)
HD465-7, HD605-7
10-63
(10)
BRAKE PIPING
HD465-7 Serial No.: 7266 and up HD605-7 Serial No.: 7113 and up
10-63-1
(12)
HD465-7, HD605-7
BRAKE PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder) Reducing valve
HD465-7, HD605-7
10-63-2
(12)
BRAKE VALVE
BRAKE VALVE
1. Pilot piston 2. Rod 3. Lower cylinder 4. Spool 5. Upper cylinder 6. Spool
A : To rear brake B : To front brake C : To transmission oil pan D : From front accumulator E : From rear accumulator
10-64
(6)
HD465-7, HD605-7
BRAKE VALVE
Operation Upper portion When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. Lower portion When brake pedal (1) is depressed, the operating 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.
Applying brake when upper valve fails Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
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 cylinder is held and the brake remains applied.
HD465-7, HD605-7
10-65
(6)
BRAKE VALVE
Lower portion When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D . Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are 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.
Brake released Upper portion When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the rear brakes. Lower portion When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the front brake.
10-66
(6)
HD465-7, HD605-7
EMERGENCY BRAKE VALVE
EMERGENCY BRAKE VALVE
1. Rod 2. Spool 3. Cylinder A. To parking brake valve P. From accumulator T. To transmission oil pan
Function This valve operates the brake depending on the parking brake release pressure controlled by the emergency brake pedal.
HD465-7, HD605-7
10-67
(10)
RELAY VALVE
RELAY VALVE
1. Spool 2. Upper cylinder 3. Lower cylinder 4. Spool A : To front brake P : From accumulator Pp: From emergency brake valve T : To transmission oil pan
Function This valve operates the front brake depending on the parking brake release pressure controlled by the emergency brake pedal.
10-68
(10)
HD465-7, HD605-7
FRONT BRAKE OFF VALVE
FRONT BRAKE OFF VALVE
WHITE
1. Connector 2. Solenoid A : To front brake P : From brake valve T : To transmission oil pan
Function This valve is installed on the brake oil circuit between the brake valve and the front brake. When the front brake off switch of the operator's seat is pressed, the solenoid is energized, and the valve cuts off the circuit between the brake valve and the front brake.
HD465-7, HD605-7
10-69
(6)
ACCUMULATOR CHARGE VALVE
ACC : To accumulator P : From hydraulic pump PP : From accumulator T : To transmission oil pan H1 : Relief valve R1 : Relief valve R3 : Main relief valve
Specification Cut in pressure : 14.2 MPa {145 kg/cm2} Cut out pressure: 20.6 MPa {210 kg/cm2} 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 accumulator. When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load of the pump.
HD465-7, HD605-7
10-71
(10)
1. Main relief valve (R3) 2. Valve body 3. Relief valve (R1)
4. Relief valve (H1) 5. Filter 6. Filter
10-72
(6)
HD465-7, HD605-7
Operation 1. When no oil is being supplied to accumulator (cut-out condition) The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so 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 oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). It also passes through orifices (17), (18) and (16), and flows to the brake oil tank.
2. When oil supplied to accumulator 1) Cut-in condition When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port C and port T are shut off. The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way. When the pressure at port P goes above the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed.
HD465-7, HD605-7
10-73
(6)
2) When cut-out pressure is reached When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. When the circuit is relieved, a pressure difference 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.
3. Main relief valve (R3) If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this set the maximum pressure in the brake circuit and protects the circuit.
10-74
(6)
HD465-7, HD605-7
ACCUMULATOR
ACCUMULATOR
1. Valve 2. Top cover 3. Cylinder 4. Piston Function The accumulator is installed between the accumulator charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop. Specifications Front brake Gas used : Nitrogen gas Charge amount : 3,500 cc Charging pressure: 11.8 MPa {120 kg/cm2} Rear brake, Parking brake Gas used : Nitrogen gas Charge amount : 4,000 cc Charging pressure: 6.9 MPa {70 kg/cm2}
HD465-7, HD605-7
10-75
(6)
SLACK ADJUSTER
SLACK ADJUSTER
1. Cylinder 2. Check valve 3. Piston A : Inlet port B : Outlet port
Specifications Piston operation pressure: 9.8 19.6 kPa {0.1 0.2 kg/cm2} Check valve cracking pressure (When cooling pressure is 0): 1.74 0.05 MPa {17.8 0.5 kg/cm2} Check valve closing pressure: 1.09 0.05 MPa {11.1 0.5 kg/cm2}
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.030 0.150 Repair limit Installed load 45.6 N {4.7 kg} Free length Installed load Clearance limit
Remedy
Clearance between body and piston 55
Shaft 0.030 0.076 Standard size
Hole +0.074 0
0.25 Replace
Slack adjuster spring
Spring coefficient 0.45 N/mm {0.046 kg/mm}
Installed length 97
10-76
(10)
HD465-7, HD605-7
SLACK ADJUSTER
Function The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. in this way it acts to keep a constant time lag when the brake is operated.
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above to set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. 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 discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke S to the left and right. 2. When brake pedal is released When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for the stroke S , and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc. When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston and dics is to 0, the greater the braking force becomes.
HD465-7, HD605-7
10-77
(6)
BRAKE
BRAKE
FRONT
1. Piston 2. Pad 3. Disc
10-78
(6)
HD465-7, HD605-7
BRAKE
Unit: mm
No.
4
Check item
Standard size Wear of pad (remaining thickness of wear material) 19.5 0.15 30
Criteria
Repair limit 3.0 Ratio of surface: 10% 0.50 Less than 27
Remedy
Replace
5 6 7
Missing portion of pad Face runout of disc (Note 1) Wear of disc (thickness of disc)
Co r re c t o r replace
Replace Open crack in radial direction 8 Damage to disc surface Electric wear, marked damage (Note 2) Correct
Note 1: If there is excessive face runout of the disc, check the front wheel bearing also. Note 2: If the depth of the scratch exceeds 1.5 mm. If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or there is protrusion. If there are vertical scratches other than concentric scratches.
HD465-7, HD605-7
10-79
(9)
BRAKE
REAR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Inner gear Retainer Outer gear Plate Disc Damper Piston Spring (for parking brake) Cylinder Cylinder (for parking brake)
10-80
(6)
HD465-7, HD605-7
BRAKE
Unit: mm
No.
11
Check item
Backlash between outer gear and plate Backlash between inner gear and disc Thickness of plate 2.4 Standard size 0.21 0.64 0.21 0.64 Standard size
Criteria
Repair limit 2.2 2.2 Repair limit 2.15 4.6 5.1 3.0 Repair limit 0.7 0.7 Repair limit 86.2
Remedy
12
13 14 15 16 17
Thickness of disc Thickness of damper Thickness of damper Distortion of disc friction surface Distortion of plate and damper friction surface Assemble thickness of plate and disc
5.1 6.9 3.4 Standard distortion Max. 0.45 Max. 0.50 Standard size 93.9
Replace
18
19
HD465-7, HD605-7
10-81
(10)
BRAKE
Function The rear brake is of an oil cooled multiple disc type, and it operates as a parking brake by use of spring. Operation of brake When the brake pedal is depressed, pressure oil from the brake valve moves brake piston (7) to the right in the direction of the arrow. This presses disc (5) and plate (4) together and generates friction between the disc and plate. The wheel is rotating together with the disc, so this friction reduces the travel speed and stops the machine.
Operation of parking brake The parking brake contained in the rear brake is structurally designed to operate mechanically by spring (8) force and to be released by hydraulic pressure. The parking releasing hydraulic pressure acts on the parking brake piston (10) from the accumulator through the brake valve and parking brake solenoid. With the parking brake switch at the driver's seat in the travel position, the parking releasing hydraulic pressure releases the parking brake by pressing the parking brake piston (10) and retracting the spring (8).
When the brake pedal is released, the pressure at the back face of brake piston (7) is released, so the piston is moved to the left in the direction of the arrow by the internal pressure, and this releases the brake.
With the parking brake switch in the parking position, the parking brake solenoid is demagnetized and the parking releasing hydraulic pressure is released. Then, the parking brake is engaged through the parking brake piston (10), brake piston (7), plate (4), and disk (5) pressed by spring force.
10-82
(6)
HD465-7, HD605-7
PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter 2. Connector 3. Solenoid assembly A : To slack adjuster P : From accumulator T : To transmission oil pan
Function The proportional reducing valve is a valve used for retarder control. It is installed between the accumulator and the slack adjuster in the brake circuit. It varies the discharge pressure of the pressure oil in accordance with the turning angle of the retarder control lever, so the retarder control can be carried out as desired.
HD465-7, HD605-7
10-83
(10)
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Connector 2. Solenoid B : To parking brake P : From emergency brake valve T : To transmission oil pan
Function The parking brake solenoid is installed in the brake oil circuit between the emergency brake valve and the rear brake. When the parking brake switch is set to PARK, the solenoid valve is demagnetized and cut off the parking brake release oil pressure. Then, the spring force of brake will operate the parking brake.
10-84
(10)
HD465-7, HD605-7
STEERING AND HOIST HYDRAULIC PIPING
10-86
(6)
HD465-7, HD605-7
1. Cross-over relief valve 2. Steering cylinder 3. Hydraulic pump (SAR(3)80+80+(1)6) 4. Demand valve 5. Hoist valve 6. Hoist cylinder 7. Hydraulic tank 8. Steering hoist filter 9. Steering control valve
HD465-7, HD605-7
10-87
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
10-88
(6)
HD465-7, HD605-7
HD465-7, HD605-7
10-89
(6)
DUMP BODY CONTROL
DUMP BODY CONTROL
1. 2. 3. 4. 5. 6.
Dump lever Hydraulic pump (SAR(3)80+80+(1)6) Hoist valve EPC valve Body positioner sensor Hoist cylinder
Function The positioner sensor senses the body operation, and from this data the retarder controller controls output to the EPC valve. The signal from the dump lever is controlled by the retarder controller, and actuates the EPC valve. The pilot pressure generated by the EPC valve moves the spool of the hoist valve and controls the hoist cylinder.
10-90
(10)
HD465-7, HD605-7
HYDRAULIC TANK
HYDRAULIC TANK
1. Breather 2. Drain 3. Oil level gauge
HD465-7, HD605-7
10-91
(6)
STEERING CONTROL VALVE
1. 2. 3. 4. 5. 6. 7.
Input shaft Upper cover Valve spool Housing Ball Stator Lower cover
8. 9. 10. 11. 12. 13. 14.
Ball Torsion bar Link Sleeve Rotor Manifold Commutator
a : From demand valve (P port) b : To tank (R port) c : To steering cylinder (RT port) d : To hoist valve (AUX port) e : To steering cylinder (LT port)
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 the steering wheel is turned to the right), valve spool (3) moves down. When this happens, the oil from the pump flows from port A through port B and enters the metering positions (6, 12). Here the flow of oil to the steering cylinders is measured, and it then passes through the steering valve. From here it flows from hole a of valve spool (3) through port
G and goes to the steering cylinders. As a result, the two steering cylinders are actuated, and the wheels turn to the right. The return oil from the steering cylinder flows from port C through port D and port E, and return to the tank. The oil remaining in the steering circuit enters port I from port J and flows to the hoist control 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 the steering wheel is turned to the left), valve spool (3) moves up. When this happens, the oil from the pump flows from port H through hole a, passes through the steering valve and enters the metering portions. Here the flow of oil to the steering cylinder is measured, and it then flows from port B to port C and flows to the steering cylinder.
As a result, the two steering cylinders are actuated, and the wheels turned to the left. The return oil from the steering cylinder flows from port G through port F and port E, and return to the tank. The oil remaining in the steering circuit enters port I from port H and flows to the hoist control valve.
HD465-7, HD605-7
10-95
CROSSOVER RELIEF VALVE
CROSSOVER RELIEF VALVE
SC1 : To steering cylinder SC2 : To steering cylinder SC3 : To steering cylinder SC4 : To steering cylinder SV1 : To steering valve SV2 : To steering valve
1. Valve body 2. Valve seat 3. Relief valve 4. Valve spring 5. Sleeve 6. Adjustment screw 7. Lock nut
10-96
HD465-7, HD605-7
STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.036 0.267 Clearance limit
Remedy
Shaft 0.030 0.104
Hole +0.163 +0.006 +0.039 0 +0.039 0
Replace bushing 0.567 1.0 Replace
Clearance between piston rod supports shaft and bushing Clearance between cylinder bottom support shaft and bushing
45
45
1.0
HD465-7, HD605-7
10-97
(9)
DEMAND VALVE
DEMAND VALVE
10-98
HD465-7, HD605-7
DEMAND VALVE
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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Spool return spring Demand spool Check valve Check valve spring Valve body Main relief valve Main relief valve spring Pilot poppet Pilot poppet spring Lock nut Adjustment screw
Unit: mm
No.
Check item
Standard size
Criteria
Repair limit Installed load 130.4 N {13.3 kg} 3.4 N {0.345 kg} Free length Installed load 120.6 N {12.3 kg} 3.1 N {0.315 kg}
Remedy
12
Spool return spring
Free length x O.D 172.2 x 29.7
Installed length 140 33.5
Replace
13
Check valve spring
42.2 x 17
HD465-7, HD605-7
10-99
(10)
DEMAND VALVE
Function This valve distributes oil which comes from the steering pump and from the work equipment pump , to the steering circuit and to the work 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.
circuit directly through the port D. The whole oil of the steering pump and part of oil from the work equipment pump flow into the steering circuit.
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 equipment pump flows into the work equipment
10-100
HD465-7, HD605-7
DEMAND VALVE
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 pressure in port B will lower.
1. 2. 3. 4. 5.
Main valve Valve seat Pilot poppet Spring Adjustment screw When the pressure in port B lowers, the orifice of the main valve (1) generates a differential pressure between ports A and B, and the pressure in port A pushes to opens the main valve (1) to release oil from port A.
Function This valve is located in the demand valve and release oil from the pump to prevent the pump from being damaged when the steering cylinder comes to the stroke end, or when an abnormal 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
HOIST VALVE
HOIST VALVE
10-102
HD465-7, HD605-7
HOIST VALVE
T P A1 B1 PA PB 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
: To tank : From flow amplifier : To hoist cylinder bottom : To hoist cylinder head : From EPC valve (pressurized side in lowering or floating operation) : From EPC valve (pressurized side in lifting operation) Body Spool Retainer Spring (lifting) Relief valve Spring (floating) Spring (lowering) Retainer Retainer Retainer Check valve
Unit: mm
No.
Check item
Standard size
Criteria
Repair limit Installed load 259 N {26.4 kg} 44 N {4.5 kg} 156 N {15.9 kg} 124 N {12.7 kg} 927 N {94.5 kg} Free length Installed load 233 N {23.8 kg} 40 N {4.1 kg} 140 N {14.3 kg} 112 N {11.4 kg} 849 N {85.1 kg}\
Remedy
12
Relief valve poppet spring
Free length O.D. 49.3
Installed length 41.9 24.5 50 32 55.5
12.8 10.9 34.5 28.7 36.0
13 14 15 16
Check valve spring Spool return spring (lifting) Spool return spring (lowering) Spool return spring (floating)
32.6 51.3 34.2 74.0
If damaged or deformated, replace the spring
HD465-7, HD605-7
10-103
HOIST VALVE
Operation 1. Hoist valve HOLD Position
Oil from the demand valve flows into chamber C. Since the hoist spool (2) blocks the path to the hoist cylinder, oil flows through chamber D to the tank.
Since both the bottom side port and the head side port of the hoist cylinder are blocked, the hoist cylinder is locked where it is.
10-104
HD465-7, HD605-7
HOIST VALVE
2. Hoist valve at LIFT Position
When the hoist lever in the cab is set to the RAISE position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the left. Therefore, oil from chamber C opens the check valve (11) and flows into chamber A.
Oil flows out of chamber A, flows in the bottom side of the hoist cylinder, extends the hoist cylinder and raise the body. On the other hand, the return oil from the head side flows out of chamber B, flows into chamber D and to the tank circuit.
HD465-7, HD605-7
10-105
(10)
HOIST VALVE
3. Hoist valve at FLOAT Position
When the hoist lever in the cab is set to the FLOAT position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the right. Then, chambers C, D, B, H and D are all connected.
Oil from the demand valve flows from chamber C through chamber B to the host cylinder and from chamber C through chamber D to the oil cooler 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. HD465-7, HD605-7
10-106
(10)
HOIST VALVE
4. Hoist valve at LOWER Position
When the hoist lever in the cab is set from the FLOAT position to the LOWER position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the right further from the FLOAT position. Therefore, oil from chamber C pushes to open the check valve (11) and flows into chamber B. Then, oil flows into the head side of the hoist cylinder through chamber B, retracts the hoist cylinder and lowers the body.
On the other hand, the return oil from the head side of the hoist cylinder flows out of chamber A and flows into chamber H. At the time of lowering, the output pressure of the solenoid valve rises over the cracking pressure of the pilot check valve, and therefore, the return oil from chamber H returns through chamber D to the tank.
HD465-7, HD605-7
10-107
(10)
EPC VALVE
EPC VALVE
1. Manual operation button 2. Solenoid assembly 3. Solenoid assembly A : To hoist valve B : From hoist valve P1 : From hydraulic tank T1 : To hydraulic tank T2 : To hydraulic tank
Function The EPC valve controlled by the retarder controller switches the pilot pressure of the hoist valve, and controls pressure, and controls the hoist valve.
10-108
HD465-7, HD605-7
HOIST CYLINDER
HOIST CYLINDER
Unit: mm
No.
Check item
Standard size
Criteria
Tolerance Standard clearance 0.089 0.407 0.103 0.393 Clearance limit
Remedy
Clearance between cylinder and bushing 170
Shaft 0.043 0.143 0.036 0.123
Hole +0.264 +0.046 +0.207 +0.067 +0.004 0.019 +0.004 0.019
0.707 0.693 1.0 1.0 Replace
2 3 4
Clearance between piston rod and bushing Clearance between piston rod support pin and bushing Clearance between cylinder support pin and bushing
100 70 70
HD465-7, HD605-7
10-109
(9)
HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING, HOIST AND HOIST CONTROL PUMP
SAR(3)80+80+(1)6
Unit: mm
No.
Check item
Model SAR(3)-80 SAR(3)-80 SAR(1)-6 SAR(3)-80 SAR(3)-80 SAR(1)-6 Model SAR(3)-80
Criteria
Standard clearance 0.10 0.15 0.10 0.15 0.060 0.149 0.06 0.144 Standard size 13 10 Tolerance 0 0.5 0 0.5 Standard delivery amount ( /min) 184 13.2 Clearance limit 0.19 0.19 0.20
Remedy
Side clearance
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
Replace 0.20 Repair limit
Depth to knock in pin
SAR(3)-80 SAR(1)-6
Rotating torque of spline shaft Model
15.8 28.5 Nm {1.6 2.9 kgm} Rotating speed (rpm) Delivery pressure MPa {kg/cm2} Delivery amount limit ( /min) 170 12.6
Discharge amount Oil: EO10-CD Oil temperature: 4555C
SAR(3)-80 SAR(3)-80 SAR(1)-6 2,500 20.6 {210}
10-110
(10)
HD465-7, HD605-7
HYDRAULIC PUMP
RETARDER COOLING PUMP

SAR(3)100+100
Unit: mm
No.
1
Check item
Clearance between gear case and side plate, gear Clearance between inside diameter of plain bearing and outside diameter of gear shaft Model SAR(3)-100 SAR(3)-100 Model
Criteria
Standard clearance 0.13 0.18 0.06 0.149 Standard size 14 Tolerance 0 0.5 Clearance limit 0.22 0.20
Remedy
Replace Repair limit 3 Depth to knock in pin SAR(3)-100 4 Rotating torque of splined shaft
13.7 23.5 Nm {1.4 2.4 kgm} Rotating speed (rpm) 2,500 Standard delivery amount ( /min.) 236 Delivery amount limit ( /min.) 216
Delivery amount Oil: EO10-CD Oil temperature: 45 55C
Model
Delivery pressure 3.9 MPa {40 kg/cm2}
SAR(3)-100
HD465-7, HD605-7
10-111
HYDRAULIC PUMP
TORQUE CONVERTER, TRANSMISSION, RETERDER COOLING AND BRAKE PUMP

SAR(3)100+(1)25
Unit: mm
No.
1
Check item
Model Side clearance Clearance between inside diameter of plain bearing and outside of diameter of gear shaft Depth to knock in pin Rotating torque of spline shaft Model SAR(3)-100 SAR(1)-25 SAR(3)-100 SAR(1)-25 SAR(3)-100 SAR(1)-25 Model SAR(3)-100 SAR(1)-25
Criteria
Standard clearance 0.13 0.18 0.10 0.15 0.06 0.149 0.06 0.144 Standard size 14 10 Tolerance 0 0.5 0.20 Clearance limit 0.21 0.19
Remedy
Replace
3 4 5
8.9 16.7 Nm {0.9 1.7 kgm} Rotating speed (rpm) 2,500 Delivery pressure MPa {kg/cm2} 20.6 {210} 20.6 {210} Standard delivery amount ( /min) 231.5 57.0 Delivery amount limit ( /min) 213.5 50.7
Discharge amount Oil: EO10-CD Oil temperature: 4555C
10-112
(10)
HD465-7, HD605-7
HYDRAULIC PUMP
EMERGENCY STEERING PUMP

SBL(1)-014
Unit: mm
No.
1
Check item
Model Clearance between gear case and side plate, gear Clearance between inside diameter of plain bearing and outside diameter of gear shaft SBL(1)-014 SBL(1)-014 Model
Criteria
Standard clearance 0.10 0.15 0.06 0.119 Standard size 10 Tolerance 0 0.5 Clearance limit 0.19 0.20
Remedy
Replace Repair limit
Depth to knock in pin SBL(1)-014
Rotating torque of splined shaft
2.0 4.9 Nm {0.2 0.5 kgm} Rotating speed (rpm) 3,500 Standard delivery amount ( /min.) 45.7 Delivery amount limit ( /min.) 42.4
Delivery amount Oil: EO10-CD Temperature: 45 55C
Model
Delivery pressure 20.6 MPa {210 kg/cm2}
SBL(1)-014
HD465-7, HD605-7
10-113
AIR CONDITIONER
AIR CONDITIONER
1. Receiver dryer 2. Air conditioner unit 3. Compressor 4. Condenser
Heating Heating is carried out using the coolant from the engine. High-temperature coolant from the hot water takeoff port flows to the air conditioner unit, and hot air is blown out by a fan. When the temperature of the coolant drops, it is returned to the hot water return port and flows as coolant for the engine. Cooling The refrigerant gas compressed and pressurized by the air conditioner compressor enters the air conditioner condenser where it is cooled by dissipating the heat It then enters the air conditioner unit and cold air is blown out by the fan. When the temperature of the refrigerant gas rises, it is returned to the compressor.
Function The air conditioner makes a pleasant operating environment for the operator and acts to reduce fatigue.
10-114
(10)
HD465-7, HD605-7
AIR CONDITIONER
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper 2. Evaporator 3. Heater core 4. Blower motor A : Hot water inlet port B : Hot water outlet port C : Refrigerant gas inlet port D : Refrigerant gas outlet port E : Dehumidified water drain port
HD465-7, HD605-7
10-115
(10)
AIR CONDITIONER
RECEIVER DRYER
1. Body 2. Dryer
10-116
HD465-7, HD605-7
AIR CONDITIONER
CONDENSER
1. Fin 2. Tube A : Refrigerant gas inlet port B : Refrigerant gas outlet port
HD465-7, HD605-7
10-117
AIR CONDITIONER
COMPRESSOR
1. Case 2. Clutch A : Suction service valve B : Discharge service valve
10-118
HD465-7, HD605-7
MACHINE MONITOR SYSTEM
Network data 1. From machine monitor to each controller Switch input data Option setting data 2. From each controller to machine monitor Display data related to each controller Service mode data Troubleshooting data 3. From transmission controller to machine monitor Model selection data
HD465-7, HD605-7
10-119
(6)
Outline With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to observe and control the condition of the machine and transmit that data as network data to the machine monitor. The machine monitor is a system to display these data and inform the operator of the condition of the machine. There are two types of display on the machine monitor: the normal mode and the service mode. The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items Meters (speedometer, tachometer) Gauges (engine water temperature, torque converter oil temperature, retarder oil temperature, fuel level) Pilot display Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (if an action code is being displayed, press machine monitor mode selector switch (2), then release it. A failure code (6-digit) is then displayed.) 3. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Other functions using the character display and the machine monitor mode selector switch to operate include the following: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and language selection. To make it easier to carry out troubleshooting of the controllers (including the monitor panel itself), a service mode function is provided. Its main content is as follows. 1. Displaying failure history for electrical system, deleting from memory Displays failure history for electrical system from each controller that is saved in machine monitor Deletes data from memory 2. Failure history for machine system Displays failure history for machine system from each controller that is saved in machine monitor 3. Real-time monitor Takes input and output signal values recognized by each controller on network and displays in real time.
4. ECMV compensation This is used for the initial adjustment of the transmission. 5. Changing replacement time for filter, oil. This changes the original setting for the replacement interval. 6. Snapshot For details, see "TESTING AND ADJUSTING, Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7. Controller initialize This function is used to set the machine monitor when the machine is shipped from the factory. The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and the sensors inputting data to the monitor panel. If the payload meter (having VHMS) is set optionally, execute display of load mass and setting of items related to the payload meter, too. For details, see "OPERATION AND MAINTENANCE MANUAL" and "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)".
10-120
(10)
HD465-7, HD605-7
MACHINE MONITOR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Speedometer Engine tachometer Retarder oil temperature gauge Torque converter oil temperature gauge Coolant temperature gauge Fuel gauge Character display Centralized warning lamp Retarder oil temperature caution lamp Torque converter oil temperature caution lamp Coolant temperature caution lamp Fuel level caution lamp Maintenance caution lamp Battery charging circuit caution lamp Steering oil temperature caution lamp (if equipped) Engine oil pressure caution lamp Retarder oil pressure caution lamp Parking brake caution lamp Machine monitor option system caution lamp Engine system caution lamp Transmission system caution lamp Retarder system caution lamp Inclination caution lamp
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42 43. 44. 45.
Seat belt caution lamp Body caution lamp Emergency steering pilot lamp Turn signal pilot lamp (right) Turn signal pilot lamp (left) Headlamp highbeem pilot lamp Shift lever position pilot lamp Shift indicator Retarder pilot lamp Lockup pilot lamp Output mode pilot lamp (power mode) Output mode pilot lamp (economy mode) Suspension mode pilot lamp (hard) (if equipped) Suspension mode pilot lamp (medium) (if equipped) Suspension mode pilot lamp (soft) (if equipped) ABS pilot lamp (if equipped) ASR pilot lamp (if equipped) Preheater pilot lamp Automatic retarder READY pilot lamp Automatic retarder set speed indicator Automatic retarder set speed unit indicator (km/h) Automatic retarder set speed unit indicator (MPH)
HD465-7, HD605-7
10-121
(10)
41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.
Travel speed compensation switch [SW1] Rotary switch [SW2] Rotary switch [SW3] Dipswitch [SW5-4] Dipswitch [SW5-3] Dipswitch [SW5-2] Dipswitch [SW5-1] Dipswitch [SW6-4] Dipswitch [SW6-3] Dipswitch [SW6-2] Dipswitch (SW6-1]
10-122
HD465-7, HD605-7
OPTION SETTING CONNECTOR DIAGRAM
52. 53. 54. 55. 56. 57. 58.
Option setting connector [OP1] Option setting connector [OP2] Option setting connector [OP3] Option setting connector [OP4] Option setting connector [OP5] Option setting connector [OP6] 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 TESTING AND ADJUSTING, Adjusting machine monitor. 2. Precautions 1) When setting, follow the instructions in TESTING 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 grommet securely to its original position.
HD465-7, HD605-7
10-123
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS

: Lighted up : Discontinuous sounds 1: The mark shows that the light is lit up while the machine monitor check switch is ON. 2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
1 When 2 machine Immediately Central Warn- monitor check after warning switch is turning ing buzzer oper- key ON. lamp ated. Related operation
No.
Display item
Display category
Device
Color
Display range/ conditions
Display method
Remarks
Meter 1 Machine speed
Movement
Scale: white Background color: black
0 80 km/h or 0 50 MPH (MPH is displayed when nonSI is used.)
Analog display
(Note)
Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.
Backlight
LED
Amber
When the small lamp is lit up.
Lit up during operation Analog display * When the overrun prevention brake is operated, the buzzer and central warning lamp is lit up. Lit up during operation
Meter 2 Engine speed
Scale: white, red MoveBackment ground color: black
0 3,400 rpm
(Note)
Backlight
LED
Amber
When the small lamp is lit up.
Gauge 3 9 Oil temperature of retarder Warning Backlight
Scale: white, red 50 150C MoveBack(120C or higher ment ground in the red zone) color: black
Analog display
(Note)
LED LED
Red Amber
At 120C or higher When the small lamp is lit up.
Lit up during warning Lit up during operation. Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.
Gauge Oil tem4 perature 10 of torque converter Warning Backlight
Scale: white, red Back50 135C Moveground (120C or higher ment color: in the red zone) black
Analog display
(Note)
LED LED
Red Amber
Lit up during warning Lit up during operation.
10-124
(9)
HD465-7, HD605-7
No.
Display item
Display category
Device
Color
Display method
When machine Immedimonitor ately check after Central switch is turning warn- Warn- opering key ON. ing ated. lamp buzzer Related operation
Remarks
Gauge Engine 5 coolant tempera11 ture Warning Backlight
Scale: white, red 50 135C MoveBack(102C or higher ment ground in the red zone) color: black
Analog display
(Note)
LED LED
Red Amber
Lit up during warning Lit up during operation. Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.
Gauge
Scale: white, red MoveBackment ground color: black
EMPTY FULL
Analog display
(Note)
6 12
Fuel level Specified level or less (remaining quantity in the tank at 120 or less) When the small lamp is lit up. 0 65535.0h Service meter Lit up during operation Lit up during operation. Operates when the engine is running. 1:1 against clock time
Warning
LED
Red
Backlight Service meter (Regular display item)
LED
Amber
* Displayed in the
"upper column" on the character display
When 65535.0h is exceeded, fixed at 65535.
Odometer (Regular Odometer display item)
* Displayed in the "lower col- Operates durumn" on the char- ing traveling. acter display
When any problem or When any prob- failure occurs, lem or failure the action Display occurs on the code is discharacter: machine, * Dis- played in the black upper column played in the Backupper and lower and remedies ground columns on the or description color: character display. of problem in green the lower column. Press machine monitor mode selector switch > during the occurrence of the problem or failure on the machine. * Appears in the upper and lower columns on the character display. The failure code (6 digits) and detection controller are displayed in the upper column and the faulty system or description of problem in the lower column.
When 999999.9 km is exceeded, fixed at 999999.9 km.
Action code
Action code
LCD
Note 1
Note 1:"HD-465" is displayed in the upper column. Note 2: "KOMATSU" is Note 2 displayed in the upper column and "SYSTEM CHECK" in the lower column.
Failure code
Failure code
For information on how to operate display, see the Operation & Maintenance Manual.
HD465-7, HD605-7
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No.
Display item
Display category
Device
Color
Display method
When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation
Remarks
Reverse travel integrating meter Reset of time to Other displays change filter and oil. Telephone number setting Language selection Night lighting Central warning lamp
LCD
Display character: black Background color: green
Press machine monitor mode selector switch " "
Switch screen by operating machine monitor mode selector switch ">" or "<".
For details, see the Operation & Maintenance Manual.
Backlight
LED
Green
When the small lamp is lit up. During system is abnormal
Dimmed down by a step when the small lamp is lit up. Lit up during warning.
LED
Red
13
Maintenance warning
LED
Red
When maintenance-related alarm is given or the time to change filter and oil has elapsed.
Lit up or turn ON and OFF
Note 1:The moment when the lamp lights up, the action code: E01 and the location where an alarm has been given appear on the character display. Note 2:For details on the target items, etc., see the Operation & Maintenance Manual.
14
Battery charging circuit warning
LED
Red
During battery charging circuit being abnormal When the steering oil temperature rises. When the engine oil pressure drops. When the retarder oil pressure drops. When the parking brake is operated. During being abnormal in machine monitor or optional controller system During being abnormal in engine control system.
Lit up during warning.
Steering oil tempera15 ture warning (option) 16 Engine oil pressure warning Retarder oil pressure warning Parking brake warning
Warning
LED
Red
LED
Red
Lit up during warning. Lit up during being abnormal. Operates when the alternator R terminal is ON. Operates when the parking brake is operated and the shift lever is in other than the "N" position. Under present conditions, used in the event of failure of the machine monitor.
17
LED
Red
(Note) (Note)
18
LED
Red
Lit up during operation.
(Note) (Note)
Machine monitor or 19 optional system warning 20 Engine system warning
LED
Red
LED
Red
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HD465-7, HD605-7
No.
Display item
Display category
Device
Color
Display method
When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation
Remarks
21
Transmission system warning Retarder system warning Inclination warning
LED
Red
Being abnormal in transmission control system During being abnormal in retarder control system When the body is lifted and inclined excessively from side to side.
22
LED
Red
23
LED Warning
Red
Lit up during warning. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. Lit up (*)
24
Seatbelt warning
LED
Red
When the seatbelt is not worn.
25
Body warning
LED
Red
See the instruction manual
(Note) (Note)
Note: Operates when the shift lever is in other than the "N" position.
26
Emergency steering
LED
Red
When the emergency steering is operated.
27
Turn signal, right
LED
Green
During operation
28
Turn signal, left
LED
Green
During operation
29
Headlight, high beam
LED Pilot
Blue
During operation
Shift 30 lever (R) position R Shift 30 lever (N) position N Shift 30 lever (D) position D 30 (6) Shift lever position 6 Shift lever position 5
LED
Green
When the shift lever is in the "R" position When the shift lever is in the "N" position When the shift lever is in the "D" position When the shift lever is in the "6" position When the shift lever is in the "5" position
* Blinks when the neutral safety is operated.
LED
Orange
Lit up
LED
Green
Lit up (*)
LED
Green
Lit up (*)
30 (5)
LED
Green
Lit up (*)
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No.
Display item
Display category
Device
Color
Display method
Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp
Remarks
Shift 30 lever (4) position 4 Shift 30 lever (3) position 3 Shift 30 lever (2) position 2 Shift 30 lever (L) position L
LED
Green
When the shift lever is in the "4" position When the shift lever is in the "3" position When the shift lever is in the "2" position When the shift lever is in the "L" position F1, F2, F3, F4, F5, F6, F7, N, R * According to the gear shift signal received from the transmission controller. * When an alarm is raised in the event of emergency escape, "E-" and the "gear speed range" are alternatively displayed. When the small lamp is lighted up. When the retarder brake is operated.
Lit up (*)
LED
Green
Lit up (*)
* Blinks when the neu tral safety is operated.
LED
Green
Lit up (*)
LED Pilot
Green
Lit up (*)
Shift indicator 31
LCD
Background color: gray
When the gear shift range signal is received from the transmission controller.
All lit up.
All lit up.
Night lighting
Backlight
LED
Amber
During operation: lit up During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF High-power mode in operation: lit up During nonoperation: turned OFF Economy mode in operation: lit up During nonoperation: turned OFF Lit up in "hard" mode
32 Retarder
LED
Orange
33
Lockup
LED
Green
When lockup of the torque converter is activated and direct drive is effective
34
Output mode (power mode)
Pilot
LED
Green
At high-power mode
35
Output mode (economy mode) Suspension mode (hard) (option)
LED
Green
At economy mode
36
LED
Green
At suspension "hard" mode
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HD465-7, HD605-7
No.
Display item
Display category
Device
Color
Display method
Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp
Remarks
Suspension mode 37 (medium) (if equipped) Suspension 38 mode (soft) (if equipped)
LED
Green
In suspension "medium" mode
Lit up in "medium" mode
LED
Green
In suspension "soft" mode
Lit up in "soft" mode
39
ABS (if equipped)
LED
Orange
When ABS is operated.
During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF When ready to be operated: lit up
40
ASR (if equipped)
LED
Orange
When ASR is operated.
41
Preheating
LED Pilot
Red
When electric intake air heater for preheating engine is operated. When automatic retarder is ready to be operated.
42
Automatic retarder being ready Automatic retarder set speed
LED
Green
43
LCD
Background color: gray
When automatic Display of set retarder switch is speed (*) turned ON.
* Zero is displayed
when the set speed is cancelled.
44
Automatic retarder unit display (km/h) automatic retarder display unit (MPH)
LED
Green
When automatic retarder switch is turned ON and the unit km/h is selected.
During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF
45
LED
Green
When automatic retarder switch is turned on and the unit km/h is selected.
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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 position before 3 seconds have passed with the starting switch at the ON position, everything will go to the normal operating condition. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have passed after the starting switch was turned to the ON position. Check function of central warning lamp, alarm buzzer, monitor lamps, and meters To check the normal display function of the machine monitor, press the machine monitor check switch to check the actuation. For details of the actuation, see "When operating machine monitor normal display functions with machine monitor check switch".
10-130
HD465-7, HD605-7
OUTLINE OF SERVICE MODE 1. Outline 1) Failure history for electrical system The system is used to check the failure history for the electrical system of each controller saved in the machine monitor. For details of the failure codes displayed for the failure history of the electrical system, see the troubleshooting section. After repairing the failure, check that the system works properly, then delete the failure history. The failure history display for the electrical system is displayed on the character display as shown below. *** : Displays order of failure history items ###### : Displays failure code $$$ : Displays number of times that applicable failure code has occurred %%%%% :Displays time that has elapsed since failure first occurr ed (Present service meter reading Service meter reading when problem first occurred = Time elapsed) @@@@@ : Displays time that has elapsed s i nc e fa i l ur e l a s t o c c ur r ed (Present service meter reading - Service meter reading when problem last occurred = Time elapsed) The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory. 2) Failure history for machine system The system is used to check the failure history for the machine system of each controller saved in the machine monitor. For details of the failure codes displayed for the failure history of the machine system, see the troubleshooting section. After repairing the failure, check that the system works properly, then delete the trouble data. The failure history display for the machine system is displayed on the character display as shown below. *** : Displays order of failure history items ###### : Displays failure code $$$ : Displays number of times that applicable failure code has occurred %%%%% : Displays time that has elapsed since failure first occurred
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@@@@@ : Displays time that has elapsed since failure last occurred The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory. 3) Real-time monitor This function is used when checking the input and output signals recognized by the controllers on the network. The real-time monitor display on the character display is as shown right. *** : Displays name of item ##### : Displays ID No. given to each item %%% : Displays data. If units are used, the unit is displayed on the right side of the data By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same time. The character display when a second item is displayed at the same time is as shown right ##### : Displays specified ID No. %%% : Displays data. If units are used, theunit is displayed on the right side of the data 4) ECMV compensation For details of this function, see TESTING AND ADJUSTING, SPECIAL FUNCTIONS OF MACHINE MONITOR. 5) Changing filter, oil replacement time For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter, oil replacement time display. This is used when changing the replacement interval. 6) Snapshot function When the VHMS controller is installed, this menu is displayed. For details, see "TESTING AND ADJUSTING, [Items related to PM Clinic], Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7) PLM setting function When payload meter (having VHMS) is set optionally, this menu is displayed. For details, see "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)". 8) Controller initialize This function is used only at the factory, so do not touch it.
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HD465-7, HD605-7
2. Method of operation For details of the method of operating each ser vice mode function, see TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR.
REMARK : When the starting switch is turned OFF, it returns to the normal mode.
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ENGINE CONTROL SYSTEM

SYSTEM DRAWING
10-134
HD465-7, HD605-7
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 actuators to control the fuel injection amount and the fuel injection timing. The machine monitor stores data transmitted from engine controller, as common data.
AISS (Automatic Idle Setting system)

Outline The AISS is a system which sets the engine low idle speed at manual or automatic to two levels according to the operating conditions of the machine. In this way it is possible to imoprove the fuel consumption and the starting and acceleration ability. Set idle speeds Low idle speed : 750 rpm High idle speed : 945 rpm High, low speed set conditions
Conditions Set to low position Engine coolant temperature above 50C and parking brake applied Engine coolant temperature above 50C and retarder lever actuated Engine coolant temperature less than 50C Parking brake released and retarder lever not actuated Operating methods Manual Automatic High/low category
Low speed
Automatic
Automatic High speed Automatic
HD465-7, HD605-7
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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 accelerator signal for the accelerator pedal, the speed signal for the transmission, and the other signals from the switches and sensors. It then automatically 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 lockup 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 modulation valve, and each clutch pack is independently 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 improving 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 2. Connector 3. Case 4. Motherboard 5. Model selector switch (rotary switch 1) 6. Model selector switch (rotary switch 2) Outline The transmission controller controls the transmission system. It has the following features and functions. 1. It has a high power mode and economy mode, and the gearshifting pattern can be selected. 2. The braking mode is the mode when the brake is used. By raising the gearshifting point and increasing the speed of the brake cooling pump, it is possible to raise the cooling effect of the retarder and make effective use of the engine brake. 3. It controls the torque converter lock-up solenoid valve and overrun prevention brake. 4. To reduce the shock when shifting gear, it outputs the throttle correction command to the engine controller when shifting gear and limits the engine speed.
5. Speed sensors are installed at three places (transmission input shaft, intermediate shaft, and output shaft). This makes it possible to detect slippage of the transmission clutches and to protect the transmission when there is any abnormality in the hydraulic system. 6. It connects to the network and shares various data with other controllers. 7. It receives input of the model selection data (what model it is mounted on), and uses the network to contact other controllers. (For details of the method of setting, see TESTING AND ADJUSTING, AND TROUBLESHOOTING.) 8. It has a self-diagnostic function which divides the input and output systems further into small parts. 9. The self-diagnostic function is displayed in two digits. 10. When an abnormality is detected, it transmits the details to the network and displays it on the other displays. 11. It uses the machine monitor to display if the failure is still existing. 12. It provides an escape function for use when there is a failure in the electrical system.
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HD465-7, HD605-7
CN1 (MIC 17-POLE) Machine Connector Number : ATC1_MIC

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Specification
ON/OFF OUT (POWER) 0 ON/OFF OUT (POWER) 2 ON/OFF OUT (POWER) 4 ON/OFF OUT (POWER) 6H ON/OFF OUT (POWER) 7H ON/OFF OUT (SIG) 8 Battery direct power supply (+24V) Controller power supply (GND) Controller power supply (+24V) ON/OFF OUT (POWER) 1 ON/OFF OUT (POWER) 3 ON/OFF OUT (POWER) 5 ON/OFF OUT (POWER) 6L ON/OFF OUT (POWER) 7L ON/OFF OUT (SIG) 9 Controller power supply (GND) Controller power supply (+24V) N.C N.C
Signal name
Remarks
Power output (+24V) for torque converter oil pressure sensor Power input (+24V) for overrun prevention brake output Power input (+24V) for transmission cut relay output Droop mode output 3 (Idling controll) Battery direct power supply (+24V) GND Power supply voltage (+24V) N.C N.C N.C Overrun prevention brake output command Transmission cut relay output Droop mode output 2 (Power/Economy selection) GND Power supply voltage (+24V)
POWER SUPPLY (+24V) FOR T/C POWER INPUT (+24V) FOR OVERRUN POWER INPUT (+24V) T/M CUT RELAY DROOP MODE OUT 3 FOR ENG BATTERY DIRECT (+24V) INPUT GND POWER INPUT (+24V)
OVERRUN OUT T/M CUT RELAY DROOP MODE OUT 2 FOR ENG INPUT GND POWER INPUT (+24V)
HD465-7, HD605-7
10-139
CN2 (MIC 21-POLE) Machine Connector Number : ATC2_MIC

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Specification
SOL power supply (+24V) SOL_OUT 4A+ SOL_OUT 4B+ SOL_OUT 5A+ SOL_OUT 5B+ A_OUT 0 SOL_OUT 0+ SOL_OUT 1+ SOL_OUT 2+ SOL_OUT 3+ A_OUT 1 SOL power supply (+24V) SOL_OUT 4A, 4B VDD_OUT (24V) SOL_OUT 5A, 5B VDD_OUT (+5V) SOL_OUT 0 SOL_OUT 1 SOL_OUT 2 SOL_OUT 3 Power GND
Signal name
SOL power input (+24V) ECMV current output (+) "1st clutch" ECMV current output (+) "4th clutch" ECMV current output (+) "2nd clutch" ECMV current output (+) "Rev clutch" N.C ECMV current output (+) "Low clutch" ECMV current output (+) "3rd clutch" ECMV current output (+) "High clutch" ECMV current output (+) "lockup clutch" N.C SOL power input (+24V) ECMV current output () "1st, 4th clutch" N.C ECMV current output () "2nd, Rev clutch" N.C ECMV current output () "Low clutch" ECMV current output () "3rd clutch" ECMV current output () "High clutch" ECMV current output () "lockup clutch" GND
Remarks
POWER INPUT (+24V) FOR SOLENOID ECMV SOLENOID "1ST" (+) ECMV SOLENOID "4TH" (+) ECMV SOLENOID "2ND" (+) ECMV SOLENOID "REV" (+)
ECMV SOLENOID "LOW" (+) ECMV SOLENOID "3RD" (+) ECMV SOLENOID "HIGH" (+) ECMV SOLENOID "L/U" (+)
POWER INPUT (+24V) FOR SOLENOID ECMV SOLENOID "1ST, 4TH" ()
ECMV SOLENOID "2ND, REV" ()
ECMV SOLENOID "LOW" () ECMV SOLENOID "3RD" () ECMV SOLENOID "HIGH" () ECMV SOLENOID "L/U" () INPUT GND
10-140
HD465-7, HD605-7
CN3 (040 20+16-POLE) Machine Connector Number : ATCA_040, ATC3B_040

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Specification
CN_CHKO PULS INPUT 0 PULS INPUT 1 PWM_IN PULS OUTPUT Sensor power supply (+5V) Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT 0(+) 1(+) 2 3 N.C
Signal name
Remarks
Transmission input shaft speed sensor Transmission output shaft speed sensor N.C Throttle modification signal output Potentio power supply Torque converter oil pressure sensor N.C Transmission oil level switch (if equipped) Emergency escape signal Steering oil temperature switch (if equipped) Transmission intermediate shaft speed sensor Engine speed sensor GND N.C GND for sensor 0() 1() 4 5 6 7 8 9 GND (Analog GND is connected) N.C Air cleaner clogging switch N.C Alternator Terminal R voltage N.C Electrolyte level switch (if equipped) Fuel level sensor N.C N.C Torque converter oil temperature sensor N.C Transmission valve oil temperature sensor N.C Accelerator pedal signal N.C N.C N.C N.C N.C
TRANSMISSION INPUT SPEED TRANSMISSION OUTPUT SPEED
THROTTLE MODIFICATION SENSOR POWER SUPPLY (+5V) TORQUE CONVERTER PRESS SENSOR
TRANSMISSION OIL LEVEL SW (if equipped) LIMP HOME SW STEERING OIL TEMP SW (if equipped) TRANSMISSION MIDDLE SPEED ENGINE SPEED SPEED GND
ON/OFF INPUT 35 PULS INPUT 2 PULS INPUT 3 PULS GND PWM_OUT Analog GND Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT
ANALOG SENSOR GND INPUT ANALOG SENSOR GND
AIR CLEANER SW
ALTERNATOR R
BATTERY LEVEL SW (if equipped) FUEL LEVEL
Analog_INPUT 10 Analog_INPUT 11 Analog_INPUT 12 Analog_INPUT 13 Analog_INPUT 14 Analog_INPUT 15 Analog_INPUT 16 Analog_INPUT 17 Analog_INPUT 18 Analog_INPUT 19 Analog_INPUT 20 Analog_INPUT 21
TORQUE CONVERTER OIL TEMP
ECMV OIL TEMP
ACCEL SIGNAL
HD465-7, HD605-7
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CN4 (040 12-POLE) Machine Connector Number : ATC4_040

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12
Specification
RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX () Flash write switch RS422 RX () RS232 C/S-NET GND RS485 () S-NET (+) S-NET (+) S-NET GND S-NET (+)
Signal name
Remarks
10-142
HD465-7, HD605-7
CN5 (040 20+16-POLE) Machine Connector Number : ATC5A_040

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CN_CHKI ON/OFF INPUT 0 ON/OFF INPUT 1 ON/OFF INPUT 2 ON/OFF INPUT 3 ON/OFF INPUT 4 ON/OFF INPUT 5 ON/OFF INPUT 6 ON/OFF INPUT 7 ON/OFF INPUT 8 ON/OFF INPUT 9 ON/OFF INPUT 10 ON/OFF INPUT 11 ON/OFF INPUT 12 ON/OFF INPUT 13 ON/OFF INPUT 14 ON/OFF INPUT 15 ON/OFF INPUT 16 ON/OFF INPUT 17 ON/OFF INPUT 18 ON/OFF INPUT 19 ON/OFF INPUT 20 ON/OFF INPUT 21 ON/OFF INPUT 22 ON/OFF INPUT 23 ON/OFF INPUT 24 ON/OFF INPUT 25 ON/OFF INPUT 26 ON/OFF INPUT 27 ON/OFF INPUT 28 ON/OFF INPUT 29 ON/OFF INPUT 30 ON/OFF INPUT 31 ON/OFF INPUT 32 ON/OFF INPUT 33 ON/OFF INPUT 34
Specification
GND
Signal name
INPUT GND
Remarks
Hydraulic tank level switch (option) Coolant level N.C N.C Transmission filter clogging switch Engine oil level switch (option) Engine oil filter clogging switch (option) Hydraulic oil filter clogging switch (option) Fill switch signal "Low clutch" Fill switch signal "4th clutch" Fill switch signal "High clutch" Fill switch signal "1st clutch" Fill switch signal "2nd clutch" Fill switch signal "3rd clutch" Fill switch signal "Rev clutch" Fill switch signal "lockup clutch" Key C signal Emergency steering operation signal 1 Heater signal N.C Shift lever signal "R" Shift lever signal "N" Shift lever signal "D" Shift lever signal "6" Shift lever signal "5" Shift lever signal "4" Shift lever signal "3" Shift lever signal "2" Shift lever signal "1" N.C N.C N.C Machine select 1 Machine select 2 Machine select 3
STEERING HOIST OIL TANK LEVEL SWITCH (OPTION) COOLANT LEVEL SWITCH
TRANSMISSION FILTER SWITCH ENG OIL LEVEL SWITCH (OPTION) ENG OIL FILTER SWITCH (OPTION) STEERING HOIST FILTER SWITCH (OPTION) FILL SIGNAL "LOW" FILL SIGNAL "4TH" FILL SIGNAL "HIGH" FILL SIGNAL "1ST" FILL SIGNAL "2ND" FILL SIGNAL "3RD" FILL SIGNAL "REV" FILL SIGNAL "L/U" KEY SWITCH C EMERGENCY STEERING RELAY 1 HEATER SIGNAL
SHIFT LEVER "R" SHIFT LEVER "N" SHIFT LEVER "D" SHIFT LEVER "6" SHIFT LEVER "5" SHIFT LEVER "4" SHIFT LEVER "3" SHIFT LEVER "2" SHIFT LEVER "L"
MACHINE SELECT 1 MACHINE SELECT 2 MACHINE SELECT 3
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GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE The relationship between each gearshift position and the automatic gearshifting range is as shown in the table below.
Gearshifting characteristics Shifting the transmission up and down is carried out according to the shift map saved in the controller memory. There are three types of shift map, depending on the condition of the input signals. The settings for each mode are as shown in the table below. HD465-7 Serial No.: 7001 7483 HD605-7 Serial No.: 7001 7181
Mode Set conditions When either of the following conditions is fulfilled 1. Brake signal ON (footbrake, retarder brake operated) 2. Accelerator pedal released When the following three conditions are fulfilled 1. Brake signal OFF (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 1. Brake signal OFF (footbrake, retarder brake not operated) 2. Accelerator pedal depressed 3. Power mode selector switch is at economy
Mode Braking mode Set conditions 1. Brake signal ON (footbrake, retarder brake operated) When the following three conditions are fulfilled 1. Brake signal OFF (footbrake, retarder brake not operated) 2. Accelerator pedal depressed 3. Power mode selector switch is at high power When the following two conditions are fulfilled 1. Brake signal OFF (footbrake, retarder brake not operated) 2. Power mode selector switch is at economy
High power mode
Economy mode
Braking mode
High power mode
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. High power mode: The high power mode uses the power of the machine to the maximum to provide the maximum payload. Economy mode: When the machine is being used under light load, such as when traveling unloaded or on flat ground, the shift-up point and shift-down point are both lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and transmission shock are improved.
Economy mode
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HD465-7, HD605-7
AUTOMATIC GEARSHIFTING GRAPH HD465-7 Serial No.: 7001 7483 HD605-7 Serial No.: 7001 7181 The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Lock-up For the lock-up ON point, the optimum point between 1,300 and 1,500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). When the machine moves off downhill F1, F2 with the accelerator pedal released, the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.
HD465-7, HD605-7
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HD465-7 Serial No.: 7484 and up HD605-7 Serial No.: 7182 and up The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Lock-up For the lock-up ON point, the optimum point between 1,300 and 1,500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). When the machine moves off downhill F1, F2 with the accelerator pedal released, the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.
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HD465-7, HD605-7
Gearshift lever positions and method of shifting 1) Gearshift lever position D When shifting up (in high power mode) i) When the gearshift lever is set at position D, the transmission is set to F2 torque converter range. ii) When the accelerator pedal is depressed, the engine speed rises and accelerates. When the transmission input shaft speed reaches 1,300 1,500 rpm, the lock-up clutch is engaged, so the torque converter is directly engaged and the transmission is set to direct travel. iii) As the engine speed rises further and reaches 2,100 rpm, the transmission shifts up to F3. While the transmission is shifting up, the engine speed is also lowered (a command is output to the engine controller) in order to reduce the shock when shifting gear. iv) Immediately after shifting up, the engine speed momentarily goes down, but as the machine accelerates, it rises again and the transmission shifts up in turn to F4 to F7 in the same way as in iii) above. When shifting down (in high power mode) i) When the load increases and the engine speed drops to 1,400 rpm, the transmission shifts down one speed. (For example, when traveling in F6, the transmission shifts down to F5.) While the transmission is shifting down, the engine speed is also raised (a command is output to the engine controller) in order to reduce the shock when shifting gear. ii) As the engine speed goes down further and the transmission shifts down in turn to F2, the torque converter lock-up clutch is disengaged and the transmission enters the torque converter drive. In the above explanation, the set speed or actuation may differ according to the travel conditions. For details, see the automatic gearshifting graph.
4) Gearshift lever position N At the neutral position, none of the transmission clutches are actuated. Gearshifting load time In the automatic shift range, to prevent mistaken operation caused by excessive variation in the speed when shifting gear, a time delay is used to prevent the gears from being shifted within the set time. The gearshifting time delay is controlled precisely by each gearshifting pattern through the use of the all-range electronic modulation system. The approximate values for the gearshifting pattern and gearshifting time delay are shown in the diagram below.
2) Gearshift lever positions 6, 5, 4, 3, 2, L The method of shifting automatically from F1 to F6 (F5, F4, F3, F2) is the same as for gearshift lever position D above. 3) Gearshift lever positions R This is the shift lever position for REVERSE travel. So, the lockup does not work. The safety functions related to travel in reverse are the directional inhibitor and reverse safety. If the operation is not correct, gearshifting is restricted, and the engine speed is reduced at a time.
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HD465-7, HD605-7
Safety functions 1) Down-shift inhibition function If gearshift lever is operated D 6-L, 6 5-L, 5 4-L, 4 3-L, 3 2-L, 2 L For example, when traveling in D (F6), even if the gearshift lever is operated to 4, the transmission does not shift directly F6 F4. It shifts down F6 F5 F4 in turn according to the travel speed. (The transmission does not jump two speed ranges if the operator makes a mistake when operating the gearshift lever. This is to prevent the engine from overrunning.) 2) Neutral safety function This circuit prevents the engine from starting if the gearshift lever is not at the N position, even if the starting switch is turned to the START position. (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 transmission is shifted to REVERSE. (To prevent overload on power train, to improve durability and reliability) 4) Power train overrun prevention rear brake function 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 reliability) 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)
6) Speed range limit function when dump body is raised. After dumping the load, if the body is not completely lowered, shifting up is limited. If the gearshift lever is at D, the machine starts in F2, and if it is at positions 6 to L, the machine starts in F1. The transmission does not shift up until the body is completely lowered. Self-diagnostic function The controller carries out self-diagnosis of the system and displays any abnormalities. If any abnormality is detected by the self-diagnosis function, the abnormality data is transmitted to the network and is displayed as an action code on the machine monitor. The transmission system caution, warning lamp, or alarm buzzer may also be actuated.
HD465-7, HD605-7
10-147
PAYLOAD METER
(CARD TYPE)
PAYLOAD METER
STRUCTURE OF SYSTEM
(CARD TYPE)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Shift lever neutral detection switch (relay) Body FLOAT signal (reterder controller) Clinometer Pressure sensor (for front left) Pressure sensor (for front right) Pressure sensor (for rear left) Pressure sensor (for rear right) Suspension cylinder Payload meter Lamp drive relay External display lamp Battery Fuse (for external display lamp) Fuse (for controller) Memory card Travel signal sensor RS232C output (PC cable communication) socket Battery charge signal (alternator terminal R)
Outline A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the external display lamps. The load mass, distance, time, time when engine was turned ON/OFF, time of occurrence/cancellation of abnormalities or warnings, and other data of each transportation cycle are automatically saved in memory. These data can be later transmitted to a PC or written in a memory card. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading.
HD465-7, HD605-7
10-151
(6)
PAYLOAD METER
(CARD TYPE)
BLOCK DIAGRAM OF PAYLOAD METER
If a dump truck having the VHMS controller is equipped with the payload meter (having VHMS) optionally, the payload meter (card type) cannot be mounted. When the payload meter (card type) is installed for the first time, replaced, or removed on a dump truck having the VHMS controller, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)". For setting procedure, see STRUCTURE, FUNCTION, and MAINTENANCE STANDARD, "Initial Setting of Payload Meter" and TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and [Items related to VHMS controller] "VHMS Initial Setting Manual (Tool)".
10-151-1
(10)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
PRINCIPLE OF CALCULATION
1. Outline A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the load mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. The load on each cylinder can be calculated from the internal pressure and sectional area of the suspension cylinder. [Load bearing on suspension cylinder] W = PB SB PT (SB ST) Where W = Load bearing on suspension cylinder PB = Bottom pressure PT = Top pressure SB = Cross-sectional area of cylinder ST = Cross-sectional area of rod Because of the structure of the suspension cylinder, PB PT Therefore, the load can be calculated as follows. W = PBST
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
2. Measurement of mass when empty (Calibration) Drive the empty dump truck at a speed of about 10 km/h for about 30 seconds, and then measure the average load and use it as the mass when empty. The reason why the mass is measured while the dump truck is traveling is that the sliding resistance of the suspension cylinders must be averaged by extracting and retracting the cylinders by changing the condition of the dump truck. The measured mass when empty is saved as a calibration data in the memory in the controller. 3. Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose, set the gearshift lever in the "N" position and set the dump control lever in the "FLOAT" position on a ground where the longitudinal inclination of the dump truck is 5. 4. Correction on slope If the dump truck is loaded on a slope, the measured mass is different from the mass measured on a level ground. To solve this problem, the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. (Correction range of inclination angle: 5) 5. Detecting distance, travel speed The travel speed and distance are detected from the travel signal sensor on the truck. a Travel signal sensor: Transmission output speed sensor
HD465-7, HD605-7
10-153
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PAYLOAD METER
(CARD TYPE)
FEATURES OF EACH DEVICE

1. Payload meter Payload meter receives signals from the pressure sensors, clinometer, body float sensor, gearshift lever (neutral sensor switch on Payload meter ), etc., calculates the load mass with the microcomputer in it, displays the calculation result on the panel, and indicates the load level on the external indicator lamps. 1) General locations of payload 1. Display 2. Communication "receiving" lamp (Rx busy) 3. Communication "transmitting" lamp (Tx busy) 4. Memory card access lamp (CARD busy) 5. Mode switch 6. Calibration/clear switch 7. Total/shift switch 8. Light/increment switch 9. Memory card 10. Cover a Communication "transmitting" lamp (3) lights up even when the communication cable is not connected to a PC or when there is defective connection. a When not inserting or removing memory card (9), always keep cover (10) closed.
10-154
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
LEFT FACE
Details of switches on left face

No. 1. 2. 3. 4. 5. 6. 7. 8. Name Load mass compensation trimmer Speed compensation trimmer Distance compensation trimmer Model selector switch Memory card use switch Clinometer use switch Mass unit setting switch Switch forcible prohibition setting switch Buzzer volume adjustment Type Rotary volume 0 F rotary selector switch 0 F rotary selector switch 0 F rotary selector switch 2-stage selector switch 2-stage selector switch 2-stage selector switch 2-stage selector switch Remarks 20% (Counterclockwise) +20% (Clockwise)
0 : 107% 7 : 107% F : 92% 0 : 107% 7 : 107% F : 92% According to model selector code table Up : Not used Down : Used Up : Not used Down : Used Up: t (Metric ton), Down: US ton (Short ton) Up : Permitted Down : Prohibited According to Permitted/prohibited setting table for switches Turn CLOCKWISE to DECREASE volume Turn COUNTERCLOCKWISE to INCREASE volume
B.
Rotatory volume
a The switches are adjusted before the machine is shipped. Only No. 7 and No. B can be adjusted. For this reason, do not touch any other switch.
HD465-7, HD605-7
10-155
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PAYLOAD METER
(CARD TYPE)
Table of model selector code

No. of model selector switches 0 (*1) 1 2 3 4 5 6 7 8 9 A B C D E HD785-3 STD Small-tire Komatsu engine HD465-5,7 STD Large-tire Komatsu engine HD405-6 STD Large-tire Komatsu engine HD985-3 STD 30:00-51 Komatsu engine HD605-5,7 STD Large-tire Komatsu engine HD785-5 STD Large-tire Komatsu engine Model HD1200-1 STD Large-tire Cummins engine HD785-3 STD Large-tire Komatsu engine HD465-5 STD Small-tire Komatsu engine HD325-6 STD Large-tire Komatsu engine
*1. The PLM on HD1200-1 has a different part No.
Permitted/prohibited setting table for switches

Left side switch No. 8 Top (permitted) Left side switch No. 5 Top (memory card not used) Bottom (memory card used) (1) Bottom (prohibited) (2)
(3)
(4)
(1) Left side switch No. 5 (top), No. 8 (top) All switches can be operated. (2) Left side switch No. 5 (top), No. 8 (bottom) Calibration, data all clear, time, date setting operations only are possible. (3) Left side switch No. 5 (bottom), No. 8 (top) All switches can be operated. (4) Left side switch No. 5 (bottom), No. 8 (bottom) Calibration, data all clear, card dump, time, date setting operations only are possible.
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
Payload meter has the following basic functions. i) Power ON (reset) When the power is turned ON, all functions are checked and displayed. a If the engine is started during the flow for this display, even there are items left to display, the display will switch after several seconds to iii) Normal operation display.
HD465-7, HD605-7
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PAYLOAD METER
(CARD TYPE)
Normal operation display

Condition of the machine Stopped Empty Traveling During loading, before reaching 50% of correct mass During loading, after reaching 50% of correct mass Stopped Traveling Stopped Traveling Traveling Loaded Stopped When dumping (*2) Abnormality, warning generated N N FLOAT
FLOAT o RAISE o LOWER o FLOAT
Shift lever position N Except N N Except N N Except N Except N
Dump lever position FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT
Payload meter display Mass display (*1) Time display Mass display Mass display Mass display Travel distance displayed in units of m from 0 160 m (each 5 m) after completion, changes to time display Mass display Aggregate mass display (*3) (Error code displayed in order of priority)
External display lamps Mass display OFF Mass display and estimated display OFF Mass display and estimated display OFF OFF Mass display OFF See Operation and Maintenance Manual
(*1) When load is less than 50% of correct mass, display shows 0 t. (*2) For details of conditions taken as dumping, see v) Content of memory (1). (*3) The aggregate mass display is shown in units of 100 t. (Rounded to the nearest 100) ii) Measuring empty mass (calibration) The mass of the machine when empty is measured and this is used as the calibration data. These data are retained even when the power is turned OFF. iii) Normal operation display (for details, see the Operation and Maintenance Manual) See the Normal operation display. iv) External display lamp drive (estimated display) The chart on the right shows the mass display level for the external display lamps during the normal operation display. The estimated display shows the estimation of the total mass when one more load is added. The applicable lamp flashes to prevent overload.
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
V) Content of memory (for details, see Operation and Maintenance Manual) a) Cycle data a The period between one dumping operation and the next dumping operation is taken as one cycle and the data are recorded. a The cycle data are recorded when the dumping conditions are fulfilled (see right). a The maximum limit for cycle data in memory is 2900 cycles.
Item Engine operation number Month Day Time Hour Time Minute Machine ID Open ID Load mass Empty travel time Empty travel distance Empty max. travel speed Empty average travel speed Empty stopped time Loading stopped time Loaded travel time Loaded travel distance Loaded max. travel speed Loaded average travel speed Loaded stopped time Dumping time Limit speed Warning items/cycle Analog spare 1 MAX electric potential MIN electric potential Average electric potential Analog spare 2 MAX electric potential MIN electric potential Average electric potential Digital spare 1 Lo frequency Digital spare 2 Lo frequency
Unit Integer Month Day Hour Minute Integer Integer t (Metric ton) or US ton (Short ton) min km km/h km/h min min min km km/h km/h min min km/h
Range 1-65535 1-12 1-31 Displayed as 0-23 Displays value and set value at time of 0-59 dumping 0-200 0-200 0-6553.5 0-6553.5 0-25.5 0-99 0-99 0-6553.5 0-6553.5 0-6553.5 0-25.5 0-99 0-99 0-6553.5 0-25.5 0-99
Displays set value at time of dumping
V V V V V V Times Times
0-4.0 0-4.0 0-4.0 0-4.0 0-4.0 0-4.0 0-255 0-255
Data processing on PC Data inside cycle are handled separately as spare signal input data.
HD465-7, HD605-7
10-159
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PAYLOAD METER
(CARD TYPE)
b) Engine ON/OFF data a Each time the engine was stopped and started is recorded. a The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets.
Item Engine operation number Year (last 2 digits) Month Day Time Hour Time Minute Year (last 2 digits) Month Day Time Hour Time Minute Aggregate load mass Total number of cycles Unit Integer Year Month Day Hour Minute Year Month Day Hour Minute t (Metric ton) or US ton (Short ton) Times Range 1-65535 Consecutive number for operation of engine
0-99 1-12 1-31 Shows when engine was switched ON Displayed as 0-23 0-59 0-99 1-12 1-31 Shows when engine was switched OFF Displayed as 0-23 0-59 0-9999000 0-9999 Total value between engine ON and engine OFF
c) Abnormality, warning data a Each time a payload meter abnormality or warning is generated or cancelled is recorded. a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets
Item Unit Range 0-65535 1-255
Engine operation number when According to 5 error code was generated Integer Frequency of generation Times after engine is switched ON Year (last 2 digits) Month Day Time Hour Time Minute Engine operation number when cancelled Year (last 2 digits) Month Day Time Hour Time Minute Year Month Day Hour (0 23) Minute Integer
0-99 1-12 Shows when error code was generated 1-31 Displayed as 0-23 0-59 0-65535
Year Month Day Hour (0 23) Minute
0-99 1-12 Shows when error code was cancelled 1-31 Displayed as 0-23 0-59
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
d) Data for aggregate load mass, total number of cycles a It is possible to calculate and record again from any desired time the aggregate load mass and total number of cycles for each time that the dumping conditions are fulfilled. a The calculation is started again for both values when the data for aggregate load mass and total number of cycles are cleared. a The maximum limit in memory for aggregate load mass and total number of cycles is 999900.0 t (Metric ton) or US ton (Short ton) and 9999 cycles respectively.
Item Aggregate load mass Total number of cycles Year (last 2 digits) Month Day Time Hour Time Minute Unit t (Metric ton) or US ton (Short ton) Times Year Month Day Hour Minute Range 0-999900.0 0-9999 Shows aggregate from time when data were cleared
0-99 1-12 1-31 Shows date and time when data were cleared Displayed as 0-23 0-59
e) Other data
Content Operator check mode set data Item Machine ID Open ID Limit speed Option code Year (last 2 digits) Month Day Time Hour Time Minute Data 1 Data 2 Data 3 Data 4 Unit Integer Integer km/h Integer Year Month Day Hour Minute Range 0-200 0-200 0-99 0-11 0-99 1-12 1-31 Displayed as 0-23 0-59 20 Characters 20 Characters 20 Characters 20 Characters Operator check mode set in input operation
Calibration performance data
Date and time when calibration was performed
User write data
Comments that can be written freely into payload meter. Note: Input and settings are possible only from PC through cable communications. (For details, see software manual.)
HD465-7, HD605-7
10-161
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PAYLOAD METER
(CARD TYPE)
f) Calibration data a These are saved in RAM each time calibration is performed. a The maximum limit in memory for calibration data is 15 sets.
Item Year Month Day Time Hour Time Minute Model selection code Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear) Tilt angle Unit Year (last 2 digits) Month Day Hour Minute Integer x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton) Range 00-99 1-12 1-31 0-23 0-59 0-F 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 9.99 +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5
Shows values and settings when calibration was performed
Shows values before compensation factor was calculated
x 180 rad Front wheel tilt compensation factor Integer Rear wheel tilt compensation factor Integer Integer Front wheel link factor Integer Rear wheel link factor t (Metric ton) Mass on spring (empty)
g) Load mass calculation data (analog data) a These are saved in RAM when the load mass calculation data are required. a The maximum limit in memory for load mass calculation data is 180 sets.
Item Year Month Day Time Hour Time Minute Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear) Tilt angle Front wheel tilt compensation factor Rear wheel tilt compensation factor Front wheel link factor Rear wheel link factor Mass on spring (empty) (Calibration value) Trimmer gain value Load mass Backup battery voltage Unit Year (last 2 digits) Month Day Hour Minute x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton) x 180 rad Integer Integer Integer Integer t (Metric ton) Integer t (Metric ton) V Range 00-99 1-12 1-31 0-23 0-59 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 9.99 +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5 0.7500 1.2500 0-6553.5 0-25.5
The above data items a) g) are retained even when the power is switched OFF.
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
vi) Forced display of aggregate load mass, total number of cycles Forced display of existing abnormalities and warnings By operating the TOTAL/SFT switch of payload meter II, it is possible to carry out forcible display of these items. For details, see the Operation and Maintenance Manual. vii) Operator check mode By operating the switch of payload meter , it is possible to carry out the following items. For details, see the Operation and Maintenance Manual. a) Memory card dump b) Data all clear c) Abnormality, warning exists/cancelled, input signal condition display d) Machine ID setting e) Open ID setting f) Limit speed setting g) Option code setting h) Time, date correction viii) Dimming of display portion It is possible to adjust the brightness of the payload meter II display portion to 10 levels with the LIGHT/INC switch. ix) Downloading saved data It is possible to download any data recorded in payload meter to a PC through a cable (ANSI/ E1A RS-232C). For details, see the PC software manual provided by Komatsu.
x) Service check mode By operating the switches of payload meter , it is possible to forcibly carry out display, setting, and correction of the following items. a) Detailed calibration data display The display shows the date, suspension pressure, etc. when the latest calibration was carried out. b) Detailed load mass calculation data display (analog data) The display shows the suspension pressure and machine angle used when calculating the present load mass. c) Memory card dump (service area) This writes all the data displayed for Items 66 and 6-7 to the memory card inserted in the machine. a This function is available only when the No. 5 switch on the left side of the controller (memory card use switches) is set for "Use" d) Data all clear (service area) This forcibly deletes all the calibration data and analog data, except for the latest calibration data. a Before clearing the data, always download the data to a PC or carry out a) Card dump. e) Input signal condition display This displays some of the signal conditions for the sensors input to payload meter and the present recognition condition of the payload meter. f) Forced initialization This forcibly deletes all the data in payload meter .
a Before carrying out this operation, check the time and date. Always carry out the operation with the machine unloaded. Do not carry out the operation unless necessary. g) Extra load mass setting when loading The extra load can be forcibly input or corrected to set the load mass when loading. Available range for setting: 9 +9 (%)
HD465-7, HD605-7
10-163
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PAYLOAD METER
(CARD TYPE)
h) Load mass fixed display and cycle data recording, load mass value setting (1) Load mass fixed display When displaying the load mass in the range shown in the table below, it is possible to input and correct to set the display for the load mass when loading is completed (when loading at least 50% of set load mass and traveling 160 m and starting to dump), not the real-time load mass.
Setting TALKS not set (option codes 0 3, 10, 11 set) When there is permission to start TALKS set option codes 4 9 set Range The time that machine is stopped when loading at least 50% of set load mass and traveling 160 m and starting to dump The time that machine is stopped from permission to move off to starting to dump The time that machine is stopped from disconnection of line to starting to dump Payload fixed display Load mass when stopped in previous cycle
Load mass last displayed in previous cycle (Final radio transmission value) Load mass last displayed in previous cycle
When disconnection of line from payload meter is requested
(2) Switching load mass fixed display in cycle data recording If the load mass fixed display in Item (1) above is applicable, it is possible to input and correct the data to set the load mass inside the cycle data in Item 6-1 to the fixed display load mass value. Possible set range: 00, 01, 10 Possible set value table
Display 00 01 10 Load mass fixed display Yes Yes No Recorded load mass value Load mass fixed display value Value when dumping load Value when dumping load
i)
Loading completion recognition travel distance setting This is used to input and correct the values to set the travel distance recognized as completion of loading by payload meter . Possible set range: 0 255 (m) Loading start recognition load mass setting This is used to input and correct the values to set the load mass recognized as the start of loading by payload meter . Possible set range: HD325-6 1 480 1,480 [ x 100 t] HD405-6 HD465-7 HD605-7 HD785-5 HD985-3 690 1,690 [ x
1 100
j)
t]
1,000 2,000 [ x
1 100
t]
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
k) Zero ton display range setting This is used to input and correct the values to set the range of the zero display on the load mass display. Possible set range: 5 10 [%: ratio of correct load mass] l) External display lamp display range setting This is used to input and correct the values to set the lamp display load mass range when displaying the load mass. Possible set range:
Lamp 1 (green) Lamp 2 (yellow) Lamp 3 (red) A : 510 255 B : A 255 C : B 255
The set value is displayed as a proportion (%) of the correct load mass. t Of the service check mode functions, the following functions can be downloaded to a PC using the PC downloading software provided by Komatsu. Calibration data Load mass calculation data (analog data) For details, see the software manual. (1) Method of operation ALways actuate the service check mode Note, c) and d) are actuated on the HD1200-1 when the parking brake is ON or when the brake lock is ON, and on machines other than the HD1200-1 when the shift lever is at the N position and when the dump lever is at FLOAT. f) is actuated only when the power is ON. a When the service mode is working, on the HD1200-1, set the parking brake to ON or the brake lock to ON, and on machines other than the HD1200-1, set the shift lever to the N position and the dump lever to FLOAT. If they are operated to other positions, the payload meter will return to the normal operation display, but in this case, the data set and input in the service check mode may not be processed correctly.
HD465-7, HD605-7
10-165
(10)
PAYLOAD METER
(CARD TYPE)
10-166
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HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
(a) Operation for calibration data display
1. Set to CHEC display, then press CAL/CLE switch (1) for at least 2 seconds. Display: CALO
2. Every time the CAL/CLE switch (1) is pressed, the display changes in the order shown on the right. 3. If MODE switch (2) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)
From CALO flashing 1 2 3 4 5 6 7 8 9 10 Last 2 digits of year for date when CAL was carried out Month and day for date when CAL was carried out Hour and minute for date when CAL was carried out
Model selection switch (decimal value) when CAL was carried out
Remarks
x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left) x 98kPa P'RR (Rear right) t t Mass on front axle x 2 (P'FL+P'RL)) (= DF 4 Mass on rear axle x 2 (= DR (P'RL+P'RR)) 4
Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X Less than 100 t: XX.X More than 100 t: XXX.X Appears when value is negative O () X.XX
Angle of tilt when CAL was 11 x 180 rad carried out 12 13 14 15 Front axle tilt coefficient Rear axle tilt coefficient Front axle link coefficient Rear axle link coefficient
X.XXX
Spring-up mass calculated All displayed values are rounded to 16 according to calibration the value given. CALO flashes 17 Returns to 1. and repeats sequence
Same number of digits as 9. and 10.
HD465-7, HD605-7
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PAYLOAD METER
(CARD TYPE)
(b) Operation for payload calculation data (analog data) display
1. Set to CHEC display, then press LIGHT/INC switch (1) for at least 2 seconds. Display: ALLO (when data in memory is less than 170 cycles) A.FUL (when data in memory is more than 170 cycles) A.FUL (when data in memory is more than 180 cycles) 2. Every time the LIGHT/INC switch (1) is pressed, the display changes in the order shown on the right. 3. If MODE switch (2) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)
From ALLO flashing or A.FUL flashing 1 2 3 4 5 6 7 Hour, minute x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left) x 98kPa P'RR (Rear right) t t Mass on front axle x 2 (= D (P'FL+P'RL)) 4 F Mass on rear axle x 2 (= D (P'RL+P'RR)) 4 R Angle of tilt when CAL was rad carried out Front axle tilt coefficient Rear axle tilt coefficient Front axle link coefficient Rear axle link coefficient t t V Spring-up mass calculated according to calibration GT Present load mass Backup battery Voltage 17 ALLO flashing Returns to (1) and repeats sequence All displayed values are rounded to the value given. X.X Same as 7. and 8. o Gain trimmer Same as 7. and 8. X.XXX Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X
Appears when value is negative
Remarks
x 180
() X.XX
9 10 11 12 13 14 15 16
10-168
(10)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
(c) Operation for memory card dump (service area)
(d) Operation for data all clear (service area)
1. Set to CHEC display, then press TOTAL/SFT switch (1) Display: Cd : dP 2. Press TOTAL/SFT switch (1) again. The main display will go out and memory card access lamp (3) will light up. When the memory card dump operation is completed, it will return automatically to the CHEC display. (End) If it is desired to stop the memory card dump operation when the display is Cd : dP, press MODE switch (2), and the display will return to CHEC without performing the memory card dump operation. The memory card dump function can be used only when the No. 5 switch (memory card use switch) on the left side of the controller is set to "Use".
1. Set to CHEC display, then press LIGHT/INC switch (1) and CAL/CLEswitch (2) at the same time for at least 2 seconds. Display: A : CLE 2. Press CAL/CLE switch (2). The display will become A.CLE (lighted up), and when the data all clear operation is completed, it will return automatically to the CHEC display. (End) If it is desired to stop the data all clear operation when the display is A : CLE, presss MODE witch (3), and the display will return to CHEC without performing the data all clear operation. a Before clearing the data, download the necessary data to a PC or carry out the card dump operation in Item (c).
HD465-7, HD605-7
10-169
(10)
PAYLOAD METER
(CARD TYPE)
(e) Operation for input signal condition display (2-d) Battery charge signal condition Display: C4:XX (lights up for 3 seconds) Engine running: C4 : oo Engine stopped: C4 : O (2-e) Analog spare input 1 signal condition Display: C5:XX (lights up for 3 seconds) X.X .... Input signal (V) O (2-f) Analog spare input 2 signal condition Display: C6:XX (lights up for 3 seconds) X.X .... Same as C5 O (2-g) Digital spare input 1 signal condition Display: C7:XX (lights up for 3 seconds) Hi:C7 : oo Lo: C7 :
1. Set to CHEC display, then press TOTAL/SFT switch (1) and CAL/CLR switch (2) at the same time for at least 2 seconds. Display: S : CHE 2. Every time CAL/CLR switch (1) is pressed, the display changes in the order shown below. (2-a) Parking brake, brake lock switch signal condition [HD1200-1] Display: C1:XX (lights up for 3 seconds) Either one ON:CL : oo Both OFF:CL : O (2-a) Shift lever position signal condition [except HD1200-1] Display: C1: XX (lights up for 3 seconds) "N":CL : oo Except "N":CL : O (2-b) Dump lever position signal condition Display: C2:XX (lights up for 3 seconds) F. FLOAT:C2 : oo Except FLOAT:C2 : O (2-c) Engine oil pressure signal condition Display: C3:XX (lights up for 3 seconds) Engine running:C3 : oo Engine stopped:C3 : O
O (2-h) Digital spare input 2 signal condition Display: C8 : XX (lights up for 3 seconds) X.X .... Same as C7 O (2-i) Travel speed display Display: C9 : XX X.X .... Travel speed (km/h) O (2-j) Travel distance display Travel distance with machine in present condition (empty or loaded) for that cycle XXXX .... (m) * If the value goes above 9999m, the display starts again from 0. O Go to next page
10-170
(10)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
( f ) Operation for performing forced initialization From previous page O (2-k) Payload meter present recognition display Counter display
Empty stopped ............. 03.01 Empty traveling............. 01.02 Loading......................... 06.03 Loaded traveling ........... 02.04 Loaded stopped............ 04.05 Dumping ....................... 05.06
Invariable May change according to N signal when dumping
O (2-l) Machine condition time display shown below
1. Set to CHEC display, then press CAL/CLR switche (11), TOTAL/SFT switch (2) and LIGHT/ INC switch (3) at the same time for at least 2 seconds. Display: :
Every time CAL/CLR switch (1) is pressed, the display advances one place in order from a) to f). a b c d e f Empty traveling Empty stopped Loaded traveling Loaded stopped Dumping Loading S1 : S2 : S3 : S4 : S5 : S6 :
2. Press CAL/CLR switch (1) for at least 2 seconds. The display becomes : (lighted up) (2 seconds), and when all the data is completely cleared, it automatically displays F.CAL. (End) After that, it carries out the process from 10.3. If it is desired to stop the forced initialization operation when the display is : , press MODE switch (4), and the display will return to CHEC without performing the forced initialization operation.
The value for the present machine recognition condition increases in minutes in real time.
3. If MODE switch (3) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)
HD465-7, HD605-7
10-171
(10)
PAYLOAD METER
(CARD TYPE)
(g) Operation for setting extra load mass when loading
(h) Operation for setting load mass fixed display and cycle data record value
1. Set to CHEC display, then press TOTAL/SFT switch (1) and LIGHT/INC switch (2) at the same time for at least 2 seconds. Display: S.5EL 2. Press CAL/CLR switch (3). Display UP : XX present set value:for + : X for : X If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct. 3. When the correction operation from Step 1. is completed, press MODE switch (4) at any time to return to the CHEC display. (End)
1. Set to UP : XX display, then press CAL/CLR switch (4) Display: PL : XX (present set value) If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct. When the correction operation is completed, press MODE switch (1) at any time to return to the CHEC display. (End)
10-172
(10)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
( i) Operation for setting loading completion recognition travel distance
( j ) Operation for setting loading start recognition load mass
1. Set to PL : XX display, then press CAL/CLR switch (4) Display: O.SEL 2. Press TOTAL/SFT switch (3). Display: XXX If it is necessary to correct the setting for the units, press LIGHT/INC switch (2) and correct. 3. Press CAL/CLR switch (4). Display: XXX If it is necessary to correct the setting for the tens, press LIGHT/INC switch (2) and correct. 4. Press CAL/CLR switch (4) again. Display: XXX If it is necessary to correct the setting for the hundreds, press LIGHT/INC switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the display will return to XXX, so it is possible to correct the units again. 6. When the correction operation from Step 1. is completed, pressMODE 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 MODE switch (1) is pressed, it displays O.XXX (input value) and returns to Step 2..
1. Set to O.SEL display, then press CAL/CLRswitch (4) Display: P.SEL 2. Press TOTAL/SFT switch (2). Display: XXXX If it is necessary to correct the setting for the tens, press LIGHT/INC switch (2) and correct. 3. Press CAL/CLR switch (4). Display: XXXX If it is necessary to correct the setting for the hundreds, press LIGHT/INC switch (2) and correct. 4. Press CAL/CLR switch (4) again. Display: XXXX If it is necessary to correct the setting for the thousands, press LIGHT/INC switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the display will return to Step 3, so it is possible to correct again. 6. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End) If it is impossible to set the input values even when MODE switch (1) is pressed, it returns to Step 1.
HD465-7, HD605-7
10-173
(10)
PAYLOAD METER
(CARD TYPE)
(k) Operation for setting 0 ton display range
1. Set to P.SEL display, then press CAL/CLR switch (4) Display: H.SEL 2. Press TOTAL/SFT switch (3). Display: XX (present value) If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct. 3. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End)
10-174
(10)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
( l) Operation for setting display range of external display lamps 6. Press CAL/CLR switch (4) again. Display: E.XXX (present value of lamp 5) If it is necessary to correct the display range for lamp 5, press LIGHT/INC switch (2) and correct. 7. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End) If it is impossible to set the input values even when MODE switch (1) is pressed, it displays d.FAL (input value) and returns to Step 2.
1. Set to H.SEL display, then press CAL/CLR switch (4) Display: E.SEL 2. Press TOTAL/SFT switch (3). Display: A.XXX (present value of lamp 1) If it is necessary to correct the display range for lamp 1, press LIGHT/INC switch (2) and correct. 3. Press CAL/CLR switch (4). Display: b.XXX (present value of lamp 2) If it is necessary to correct the display range for lamp 2, press LIGHT/INC switch (2) and correct. 4. Press CAL/CLR switch (4) again. Display: C.XXX (present value of lamp 3) If it is necessary to correct the display range for lamp 3, press LIGHT/INC switch (2) and correct. 5. Press CAL/CLR switch (4) again. Display: d.XXX (present value of lamp 4) If it is necessary to correct the display range for lamp 4, press LIGHT/INC switch (2) and correct.
HD465-7, HD605-7
10-175
(10)
PAYLOAD METER
(CARD TYPE)
2. Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the valve (2) installed to the suspension and remove only pressure sensor (1). When removing or installing pressure sensor (1), be careful not to let valve (2) rotate. When removing pressure sensor (1), the action of valve core (3) prevents the suspension pressure 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
(6)
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
3. Clinometer To carry out compensation on slopes, the clinometer measures the tilt angle of the chassis in the front-to-rear direction.
The output characteristics of the clinometer are as 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
PAYLOAD METER
(CARD TYPE)
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 of display priority 1 Content Dump lever at position other than FLOAT (except when dumping) Judgement standard Error code display Controller display b-FL ON External lamp display All flash Cancellation of display When removed Timing for display [for HD1200-1] When parking brake or brake lock is ON [for HD1200-1] When parking brake or brake lock is OFF Removal detection only for card dump Except during loading Except during loading
b-FL ON
When removed
Memory card removed Drop in backup battery voltage Cycle data memory FULL Engine ON/OFF data memory FULL Abnormality, warning data memory FULL Aggregate payload, number of cycles data memory FULL
Cd flashes
When removed When removed See (*1)
Defective contact or voltage below 2.7 V See (*1)
F-09 flashes
See (*1)
Disconnection in terminal R Abnormality in sensor power source (18 V)
Output below 2 V when engine is running Output is less than 15 V and power source voltage is more than 20 V Suspension pressure sensor input signal is 0 kg/cm2 or below
F-18 flashes
All flash
When removed When removed
When engine is running Any time
F-20 flashes
All flash
Short circuit with ground, disconnection in front left suspension pressure sensor system Short circuit with ground, disconnection in front right suspension pressure sensor system Short circuit with ground, disconnection in rear left suspension pressure sensor system Short circuit with ground, disconnection in rear right suspension pressure sensor system
F-21 flashes
All flash
When removed
Any time
F-22 flashes
F-23 flashes
10
F-24 flashes
10-180
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
Saving abnormality, warning data (PC software display code)
Remarks 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 Rated voltage: 3.6 V
Records (000-009) Records (000-011) (000-012) (000-013) (000-014)
Records (000-018) Records (000-020)
Calibration cannot be performed when there is abnormality Calibration cannot be performed when there is abnormality
Records (000-021)
(000-022)
(000-023)
(000-024)
HD465-7, HD605-7
10-181
PAYLOAD METER
(CARD TYPE)
Order of display priority 11
Content Short circuit with power source in front left suspension pressure sensor system Short circuit with power source in front right suspension pressure sensor system Short circuit with power source in rear left suspension pressure sensor system Short circuit with power source in rear right suspension pressure sensor system Short circuit with ground, disconnection in clinometer system Short circuit with power source in clinometer system Calibration not performed or abnormality in RAM Short circuit in external display lamp No. 1 relay Short circuit in external display lamp No. 2 relay Short circuit in external display lamp No. 3 relay Short circuit in external display lamp No. 4 relay Short circuit in external display lamp No. 5 relay Defective cycle data payload (*2) Over speed limit
Judgement standard Suspension pressure sensor input signal is 19.6 MPa {200 kg/cm2} or more
Error code display Controller display F-25 flashes External lamp display All flash Cancellation of display When removed Timing for display Any time
12
F-26 flashes
13
F-27 flashes
14
F-28 flashes
15
Clinometer input signal above +100 Clinometer input signal above 100 EG Calibration data in memory damaged When coil is conducting electricity, relay coil short circuits with power source
F-31 flashes
All flash
When removed
Any time
16
F-32 flashes
17
F CAL flashes F-41 flashes F-42 flashes F-43 flashes F-44 flashes F-45 flashes
All flash
When removed When removed
Any time
18 19 20 21 22 23
See Remarks column
Except when loading (for external display lamps, see Remarks column)
See (*2)
L.bad flashes SP:SP flashes F-71 F-73 F-80 F-81 F-91 F-92 F-93 F-94 F-95 F-96 F-97 F-98 F-99
Start of empty travel Set value 2km/h When removed
Start of dumping start of empty travel When problem occurs
24
Travel speed is over set speed limit
25
Defective communications or defective setting of option code
10-182
HD465-7, HD605-7
PAYLOAD METER
(CARD TYPE)
Saving abnormality, warning data (PC software display code) Records (000-025)
Remarks Calibration cannot be performed when there is abnormality
(000-026)
(000-027)
(000-028)
Records (000-031) (000-032)
Applicable only when clinometer "use" switch is at "use" Calibration cannot be performed when there is abnormality Payload calculation stopped while problem occurs
External display lamps actuated as follows Applicable lamp Machine stopped: Always ON Machine traveling: OFF Other lamps during loading: Specified actuation Other than loading Machine stopped: Flashes Machine traveling: OFF
Records (000-019) Records (000-041) (000-042) (000-043) (000-044) (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 STEERING SYSTEM

1. Timer 2. Batter 3. Flow switch 4. Emergency steering motor 5. Emergency steering pump 6. Demand valve
Outline If the engine should stop when the machie is traveling, or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit, the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering, thereby making it possible to use the steering. This system can also be operated manually.
10-184
(12)
HD465-7, HD605-7
FLOW SWITCH
1. Wire cable 2. Housing 3. Magnet 4. Pivot pin 5. Disc 6. Spring 7. Lead switch
Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. If the flow of oil inside the hydraulic piping drops below the specified level or stops, the flow switch detects this and actuates the lead switch.
HD465-7, HD605-7
10-185
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
RELAY TIMER
1. Dial 2. Lock 3. Pin
Set time: 1 seconds
Outline The relay timer is a delay timer to prevent the emergency steering system from being actuated when the flow switch is acuated mistakenly by the pulse of the oil or 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
(9)
1. Timer 2. Batter 3. Steering oil pressure switch 4. Emergency steering motor 5. Emergency steering pump 6. Demand valve
Outline If the engine should stop when the machie is traveling, or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit, the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering, thereby making it possible to use the steering. This system can also be operated manually.
10-187-1
(12)
HD465-7, HD605-7
FLOW SWITCH
1. Wire cable 2. Housing 3. Magnet 4. Pivot pin 5. Disc 6. Spring 7. Lead switch
Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. If the flow of oil inside the hydraulic piping drops below the specified level or stops, the flow switch detects this and actuates the lead switch.
HD465-7, HD605-7
10-187-2
(12)
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.
10-187-3
(12)
HD465-7, HD605-7
RELAY TIMER
1. Dial 2. Lock 3. Pin Set time: 1 seconds
Outline The relay timer is a delay timer to prevent emergency steering system from malfunctioning. After the current flows in the coil for the time set by the timer, the relay contacts are switched.
HD465-7, HD605-7
10-187-4
(12)
AUTOMATIC SUSPENSION SYSTEM
1. Dump control lever 2. Retarder controller 3. Suspension cylinder 4. Solenoid valve 5. Hydraulic cylinder
Outline The front suspension mode (damper force) is automatically switched according to the travel condition and load condition to give a more comfortable ride to the operator and to improve the travel stability. For details of the internal mechanism of the suspension, see SUSPENSION
10-188
(6)
HD465-7, HD605-7
AUTOMATIC SUSPENSION MODE SELECTION CONTROL

With the front suspension, the mode (damping force) is automatically changed according to the travel conditions and load conditions to ensure a comfortable ride and to improve the travel stability of the machine. The control patterns and functions of the modes (damping force) are as shown in the table below. When a liner has been installed to the body for HD465 to make it equivalent to the rock body, the increased load on the springs will affect the loaded/unloaded judgement in the table below. In this case, select the machine model HD605 by the switch for the transmission control system.
S:Soft M:Medium H:Heard Set mode Control pattern Function Content of control S Distinguishing empty/loaded Anti-roll To set damping force according to load on machine To prevent the chassis from rolling when turning at high speed Internal pressure of front suspension cylinder is measured and compared with standard valve This detects the travel speed and steering angle, and switches the mode according to certain conditions. (Not controlled when traveling empty) Empty M H S Loaded M H
(When turning)
Anti-dive
To prevent nose-diving when braking To prevent the front from lifting up when dumping To improve stability when traveling at high speed
The damping force is made stronger when the brakes are applied. The damping force is made stronger when the dump body control lever is at any position except FLOAT. Detects travel speed and selects damping force. (No control when traveling empty)
(Brake (Brake ON) OFF)
(Brake (Brake ON) OFF)
Anti-lift
(Float)
(Other
than Float)
(Float) (Other
than Flot)
High speed stability
HD465-7, HD605-7
10-189
(10)
AUTO SUSPENSION SOLENOID VALVE
1. Connector 2. Solenoid A : To hydraulic cylinder head B : To hydraulic cylinder bottom P : From pump T : To transmission oil pan
Function The automatic suspension solenoid valve is installed in the circuit between the hydraulic pump and the suspension cylinder. The valve switches oil pressure of the hydraulic cylinder which is installed to the front suspension, according to signal from the retarder controller. Two solenoid valves are combined to select three modes of Soft, Medium and Hard.
10-190
(6)
HD465-7, HD605-7
STEERING ANGLE SENSOR (If equipped)
1. Body 2. Tube 3. Connector Principle of operation: Magnetic contactless proximity switch Form of output: Turning ON when object of sensing approaches.
Function A round disc with teeth like a comb is installed to the steering column. As this disc passes through the slit in the sensor, the sensor outputs a pulse signal. The suspension controller can obtain the steering speed from the number of pulses per time.
PRESSURE SENSOR
Function The pressure sensor is installed to the suspension cylinder. If pressure is applied through the pressure receiving part to the diaphragm of the pressure sensing unit, the diaphragm is deformed. A bridge of strain gauges is formed in front of the diaphragm so that the resistance of the strain gauges will change when the diaphragm is deformed. A constant voltage is applied to the strain gauges. The change of the resistance of the strain gauges is sent as a change of the voltage to the amplifier. The amplifier amplifies the change of the voltage and outputs it to the controller.
HD465-7, HD605-7
10-191
(10)
RETARDER CONTROL SYSTEM
10-192
(6)
HD465-7, HD605-7
RETARDER CONTROLLER
1. 2. 3. 4. 5.
Self-diagnostic display window Rotary switch Motherboard Case Connector
4. Automatic retarder speed control (ARSC) This device controls retarder braking force by movement of electromagnetic proportional control valve to maintain the machine speed set by the automatic retarder machine speed setting switch when driving down hills. 5. Automatic Suspension Control The controller switches output to the automatic suspension solenoid valve according to the travel conditions and loading conditions such as unloading or loading, turning. braking, etc. according to the signal sent from various sensors, and the controller switches damping force of front suspension in three stages of Soft, Medium and Hard. 6. ASR Control (if equipped) The controller detects slips of the drive wheels according to machine speed and steering angle of the right and left drive wheels, and the controller controls the ASR proportional valve so that the speed difference between the both wheels become constant. The brake torque is transmitted to the lower speed wheel by braking the higher speed slipping wheel, so the traveling ability is improved.
Outline The retarder controller has the following functions. 1. Retarder control The electromagnetic proportional valve is controlled according to the operating angle of the retarder control lever and actuates the retarder. 2. Overrun prevention, retarder control when there is transmission abuse The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount. 3. Hoist control This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) according to the position of the dump control lever and actuates the dump body.
HD465-7, HD605-7
10-193
(10)
7. Transmission of network data 1) Retarder actuation, float caution, parking brake actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor panel. 2) The overrun prevention, retarder command when there is abuse, and other data sent from the transmission controller are received. 3) The reverse inhibit, and other data are transmitted to the transmission controller.
10-194
(6)
HD465-7, HD605-7
CN1
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 D_OUT_1 D_OUT_3 D_OUT_5 D_OUT_6L D_OUT_7L D_OUT_9
Specification
D_OUT_0 D_OUT_2 D_OUT_4 D_OUT_6H D_OUT_7H D_OUT_8
Signal name
Automatic suspension solenoid 1 Automatic suspension solenoid 2
Function
H side (1A) H side (1A) H side (1A) 24V/L side 24V/L side
Remarks
AUTO SUS SOL A AUTO SUS SOL B
Push button retarder switch Battery direct Power GND Power supply +24V Front brake cut solenoid Kick out solenoid Hoist changeover valve Brake cut relay output Sensor power supply Body float signal Power GND Power supply +24V
L side (150mA) Battery direct IN GND Power supply +24V H side (1A) H side (1A) H side (1A) H side/GND H side/GND L side (150mA) GND Power supply +24V
P/B RETARD SW (FOR E/G Controller)
FRONT BRAKE CUT SOLENOID KICK OUT SOLENOID DUMP CHANGE CONTROL VALVE BRAKE CUT RELAY SENSOR POWER BODY FLOAT SIG (FOR PLM)
CN2
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 A_OUT_0 A_OUT_1 A_OUT_2 A_OUT_3 A_OUT_5A, 5B Retarder lever, steering angle potentio power +5V A_OUT_4A, 4B Suspress, steering speed sensor power +12V A_OUT_4A+ A_OUT_4B+ A_OUT_5A+ A_OUT_5B+ V_OUT A_OUT_0+ A_OUT_1+ A_OUT_2+ A_OUT_3+ V_OUT Power supply +24V Rear wheel retarder EPC output EPC output for ASR (left rear wheel) EPC output for ASR (right rear wheel) Hoist EPC valve
Specification
Signal name
Solenoid power supply +24V Shut off valve
Function
Solenoid power supply 0 1A 0 1A 0 1A 0 1A Interlocked with A_OUT0 (0 5V) 0 1A 0 1A 0 1A 0 1A Interlocked with A_OUT1 (0 5V) Solenoid power supply A_OUT4AB (COM) Sensor power supply A_OUT5AB (COM) Sensor power supply +5V (400mA) A_OUT0 (COM) A_OUT1 (COM) A_OUT2 (COM) A_OUT3 (COM) Power GND
Remarks
SHUT OFF VALVE (+) (FOR ASR)
RETARD BRAKE VALVE (L) (+) (MANU AND AUTO) RL BRAKE VALVE (+) (FOR ASR) RR BRAKE VALVE (+) (FOR ASR) DUMP CONTROL PCV (+)
Shut off valve () (option) (option)
RETARD BRAKE VALVE () RL BRAKE VALVE () (OPTION) RR BRAKE VALVE () (OPTION) DUMP CONTROL VALVE ()
HD465-7, HD605-7
10-195
(6)
CN3
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 A_IN_0() A_IN_1() A_IN_4 A_IN_5 A_IN_6 A_IN_7 A_IN_8 A_IN_9 A_IN_10 A_IN_11 A_IN_12 A_IN_13 A_IN_14 A_IN_15 A_IN_16 A_IN_17 A_IN_18 A_IN_19 A_IN_20 A_IN_21 Accelerator signal Hoist lever potentiometer 1 Body potentio Hoist lever potentiometer 2 ARSC set switch Manual retarder lever signal Suspension pressure sensor (left front wheel) Suspension pressure sensor (right front wheel) Retarder oil temperature sensor PWM_OUT Analog sensor GND GND(Analog) A_IN0 () A_IN1 () Pull down/(up) Pull down/(up) Pull down Pull up (1K) Pull up (4.7K) Pull up (150) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull down Pull down Pull down Pull down Pull down Pull down ACCEL SIGNAL (T/M) (FOR ARSC/ASR) DUMP LEVER POTENTIO1 BODY POSITION SENSOR DUMP LEVER POTENTIO2 ASRC SET SW (FOR ARSC) MANUAL RETARD LEVER SUS PRESS (FL) SUS PRESS (FR) RETARD OIL TEMP S/T ANGLE POTENTIO () A_IN_0 A_IN_1 A_IN_2 A_IN_3 A_IN_35 PLS_AC_IN_2 PLS_AC_IN_3 Hoist lever, body potentio ARSC set switch power +5V Steering angle potentiometer Accumulator oil pressure sensor (front) Potentio power +5V (20mA) A_IN0 (+) A_IN1 (+) Pull down/(up) S/T ANGLE POTENTIO (+) (FOR ASR) ACC OLL PRESS (FRONT) ACC OLL PRESS (REAR) S/T SPEED SENSOR (FOR AUTO SUS) T/M OUTPUT SPEED (+)
Specification
D_IN PLS_AC_IN_0 PLS_AC_IN_1 PWM_IN
Signal name
Function
Connector check 0 (pull up)
Remarks
CONNECTOR CHECK 1 WHEEL SPEED (RL) (FOR ASR) WHEEL SPEED (RR) (FOR ASR)
Wheel speed sensor (left rear wheel)
Wheel speed sensor (right rear wheel)
Accumulator oil pressure sensor (rear) Pull down/(up) Steering angle speed Transmission output shaft speed sensor Speed GND Pull up/down4 GND
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HD465-7, HD605-7
CN4
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12
Specification
Signal name
RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX () Flash switch (ON/OFF) RS422 RX () GND (serial) RS485 () S-NET (+)
Function
RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX () Flash switch (ON/OFF) RS422 RX () GND (serial) RS485 () S-NET (+)
Remarks
HD465-7, HD605-7
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CN5
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 D_IN_0 D_IN_1 D_IN_2 D_IN_3 D_IN_4 D_IN_5 D_IN_6 D_IN_7 D_IN_8 D_IN_9 D_IN_10 D_IN_11 D_IN_12 D_IN_13 D_IN_14 D_IN_15 D_IN_16 D_IN_17 D_IN_18 D_IN_19 D_IN_20 D_IN_21 D_IN_22 D_IN_23 D_IN_24 D_IN_25 D_IN_26 D_IN_27 D_IN_28 D_IN_29 D_IN_30 D_IN_31 D_IN_32 D_IN_33 D_IN_34 Service brake switch Retarder switch Parking brake switch Lever validation 1 switch Lever validation 2 switch Retarder cooling filter switch Inclination switch Memory clear switch Engine starting signal ABS signal Brake wear sensor (left rear wheel) Brake wear sensor (right rear wheel) Exhaust brake command (from transmission controller) Overrun prevention command (from transmission controller) ASR actuating pressure switch (left rear wheel) ASR actuating pressure switch (right rear wheel)
Specification
Signal name
Function
Connector check 1 (to GND) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull down Pull down Pull down Pull down/potentio power +5V Pull up/down 1 Pull up/down 1 Pull up/down 1 Pull up/down 1 Pull up/down 2 Pull up/down 2 Pull up/down 2 Pull up/down 2 Pull up/down 3 Pull up/down 3 Pull up/down 3 Pull up/down 3 Pull up/down 4 Pull up/down 4 Pull up/down 4
Remarks
CONNECTOR CHECK 2
SERVICE BRAKE PRESS SW RETARD BRAKE PRESS SW P/B, EMERG BRAKE PRESS SW LEVER VALIDATION SW 1 LEVER VALIDATION SW 2 SYSTEM FILTER RETARD COOLING FILTER INCLINATION SW MEMORY CLEAR SW KEY SW (E/G START SIGNAL) COMMAND FROM ABS BRAKE WEAR RL BRAKE WEAR RR EXHAUST BRAKE COMMAND (FROM T/M) OVERRUN COMMAND (FROM T/M) RL BRAKE PRESS SW (FOR ASR) RR BRAKE PRESS SW (FOR ASR)
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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 corresponding to this is output to the electromagnetic proportional valve to actuate the retarder. Overrun prevention, retarder control when there is transmission abuse The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount.
HD465-7, HD605-7
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Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
A: To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger output) is set to a high value. B: To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a high value. C: In the range where the retarder is normally used, the output is proportional to the angle of the lever. D: To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low value.
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HD465-7, HD605-7
HOIST CONTROL FUNCTION

HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve are controlled according to the operation of the dump control lever and operate the dump body. 2. Lever positioner function The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER. If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD position. If the lever is kept at the RAISE position, the RAISE output continues to be given. 3. Body seating speed control When the dump body is lowered and reaches the position just before it is seated, the area of opening 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
4. Control when starting switch is turned to ON, OFF, or START Starting switch at ON: The output is set to HOLD, regardless of the position of the lever. If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD. Starting switch at OFF: The dump body is held in position regardless of the position of the lever. Engine started: Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever. After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
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5. Reverse inhibit function The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the judgment through the network to the transmission controller. "FLOAT OUTPUT" and "SEATED" o Reverse travel permitted "NO FLOAT OUTPUT" or "NOT SEATED" o Reverse travel not permitted 6. Calibration function To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the dump body seating and the body cylinder stopper condition. After adjusting the installation of the body potentiometer or after replacing the retarder controller, carry out calibration in the following order. Order of dump control calibration (hydraulic oil temperature: 80 90C) 1) Lower the dump body completely, run the engine, and keep the lever at FLOAT for at least 5 seconds. (Check that the float caution has gone out.) 2) Operate the lever to the RAISE position until and raise the dump body until it contacts the stopper. Keep the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds. 3) Lower the body to the seat, and then keep the lever at the FLOAT position for at least 5 seconds. 4) Run the engine at low idling and operate RAISE o FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times. 5) Run the engine at high idling and operate RAISE o FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times.
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HD465-7, HD605-7
SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
1. Magnet 2. Locknut 3. Wiring harness 4. Connector
Function The engine speed sensor is installed to the ring gear of the flywheel housing. It uses the rotation of the gear teeth to generate a pulse voltage and transmits a signal to the transmission controller.
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HD465-7, HD605-7
SENSORS, SWITCHES
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 voltage is impressed between the No. 1 3 pins of both potentiometers. A voltage signal corresponding to the angle of the accelerator pedal is sent from the No. 2 pin to the engine and transmission 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
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SENSORS, SWITCHES
RETARDER OIL TEMPERATURE SENSOR
1. 2. 3. 4.
Thermistor Plug Wiring harness Connector
Function The sensor is installed to the retarder piping. It take the change in resistance of the thermistor 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 display 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.
COOLANT LEVEL SENSOR
1. Float 2. Sensor 3. Connector
Function This sensor is installed to the top of the radiator, and when the coolant level goes below the specified level, the float goes down and the switch goes OFF. The maintenance caution lamp lights up and the character display shows message to warn of abnormality.
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HD465-7, HD605-7
SENSORS, SWITCHES
TRANSMISSION OIL FILTER CLOGGING SENSOR
1. Body 2. Tube 3. Connector A : Low pressure pickup port B : High pressure pickup port
Function This sensor are installed to each filter, and when the filter becomes clogged, and the difference in pressure between the low-pressure side and high-pressure side reaches the specified pressure, the switch goes OFF. The maintenance caution lamp lights up and the character display shown message to warn of abnormality. Actuating pressure: 275 kPa {2.8 kg/cm2} Principle of switch: Pressure difference sliding piston type
STEERING OIL PRESSURE SWITCH (FOR AUTOMATIC EMERGENCY STEERING SYSTEM)
1. Piston 2. Body 3. Switch 4. Connector
Function The steering pressure switch is installed to the steering and hoist piping. If the oil pressure in the steering circuit lowers below the set level while the engine is running, the steering pressure switch starts the electric pump to secure the oil pressure for steering.
HD465-7, HD605-7
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SENSORS, SWITCHES
FUEL LEVEL SENSOR
1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer
Function The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display of the monitor panel reaches a certain level, a warning lamp flashes.
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HD465-7, HD605-7
SENSORS, SWITCHES
AIR CLEANER CLOGGING SENSOR
1. Indicator 2. Spring 3. Adapter
Function The air cleaner clogging sensor is installed to the outward port of the air cleaner. If the air cleaner becomes clogged and reaches the set pressure (negative pressure), the maintenance caution lamp lights up and character display shows message to warn of the abnormality.
HD465-7, HD605-7
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SENSORS, SWITCHES
BODY POSITIONER SENSOR
1. Bearing 2. Rotor 3. Connector
Function The body position sensor is installed to the rear 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.
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HD465-7, HD605-7
SENSORS, SWITCHES
TILT SWITCH
1. Magnet 2. Plate 3. Gasket 4. Print card 5. Bracket 6. Plate 7. Plate 8. Plate 9. Connector
Function If the chassis tilts to the left or right, the disc magnet moves to the left or right. If the chassis tilts into the roll-over danger range, either the left or right switch is turned OFF. If the dump lever is operated to the RAISE position in this condition, the lamp lights up and the buzzer sounds to warn of the danger.
HD465-7, HD605-7
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DUMP LEVER
DUMP LEVER
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HD465-7, HD605-7
DUMP LEVER
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
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DUMP LEVER
Function When lever (1) is operated, rod (18) moves up or down according to the amount the lever is operated, and rotates potentiometer (16). The amount the control lever is operated (travels) is detected by the potentiometer, and this is sent as a signal voltage to the controller. One potentiometer is installed and outputs two related signal voltages as shown in the "Output voltage characteristics" graph. Operation 1. Dump lever operated to FLOAT When LOWER rod (2) is pushed by lever (1) and moves down, ball (14) contacts protrusion a of rod (11) during the stroke. (Before start of actuation 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 protrusion b of rod (19), so the lever is held at the FLOAT position.
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HD465-7, HD605-7
DUMP LEVER
2. Dump lever FLOAT canceled When lever (1) is returned from the FLOAT position, it is pushed down by a force greater than the holding force of rod (19), detent spring (20), retainer (13), and ball (14). 3. Dump lever operated to LOWER When lever (1) is operated further from the FLOAT position, it moves to the LOWER position. Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated. Lever (17) and rod (19), which are installed to the rotating shaft of potentiometer (16), are interconnected, so a voltage matching the up or down movement of the rod is output from potentiometer (16).
4. Dump lever operated to RAISE When RAISE rod (18) is pushed by lever (1) and moves down, ball (14) contacts protrusion a of rod (19) during the stroke. (Before start of actuation of mechanical detent) When rods (18) and (19) are pushed in further, ball (14) is being held by detent spring (20). While pushing retainer (13) up, it escapes to the outside, and rod (19) passes over protrusion a. When this happens, rod (2) on the opposite side is pushed up by spring (4). When an electric current is flowing to solenoid (19), if rod (2) is pushed up, nut (10) is held in contact with bushing (8). As a result, rod (2) is held at the pushed up position, so even if the lever is released, it is held at the RAISE position.
5. Dump lever RAISE canceled When lever (1) is returned from the RAISE position, it is pushed down by a force greater than the attraction force of the solenoid. Or, when the solenoid power source is turned OFF, the RAISE position is canceled and the lever returns to the N position.
HD465-7, HD605-7
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VHMS CONTROLLER BLOW-BY PRESSURE SENSOR
VHMS CONTROLLER
For details of the basic precautions, outlines, method of sending and receiving data, and the procedure for the initial setup, see TESTING AND ADJUSTING. Specifications 1. Voltage of power supply : DC20V - DC30V 2. Size (mm) : W272 x D169 x H72 Function The VHMS controller collects and stores signals from each sensor and signals from the machine controller. It also gives commands for transmitting the accumulated data through the communications satellite.
BLOW-BY PRESSURE SENSOR

Specifications 1. Voltage of power supply : DC5V 2. Output voltage : 0.5V (engine stopped) or more 3. Size: Mount (portion a) : R 1/4 : Outside diameter of seat receiving pressure : 37 mm : Length of cable: 1,110 mm Function The blow-by sensor converts the pressure inside the engine crankcase into a voltage and inputs this into the VHMS controller as the blow-by pressure.
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HD465-7, HD605-7
ENGINE OIL TEMPERATURE SENSOR
ENGINE OIL TEMPERATURE SENSOR

Specifications 1. Type of sensor : Thermistor 2. Range of measurement : 40 130 C : 80 130 C (guaranteed precision 2 C) 3. Max. power consumption: 0.5 mW 4. Pressure resistance : 4.9 MPa {50 kg/cm2} 5. Temperature range : --30 to 140 C 6. Performance table
Tempera- Resis- Tempera- Resis- Tempera- Resisture tance ture tance ture tance (C) (kz) (C) (kz) (C) (kz) 30 40 50 60 70 35.27 24.28 17.05 12.20 8.884 80 85 90 95 100 6.571 5.682 4.931 4.293 3.750 110 115 120 125 130 2.887 2.544 2.248 1.992 1.769
a : Heat sensing portion of sensor, outside diameter of mount R 1/4 Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change in temperature to the VHMS controller as a change in the resistance of the thermistor.
HD465-7, HD605-7
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EXHAUST TEMPERATURE SENSOR/AMP AMBIENT TEMPERATURE SENSOR
EXHAUST TEMPERATURE SENSOR/AMP

Specifications 1. Rated voltage : DC24V 2. Detection temperature range : 100 1,000 C : 300 800 C (guaranteed accuracy 10 C) 3. Output voltage characteristics: See table below 4. Actuation temperature range : --40 to 110 C 5. Consumption current : Max. 30 mA a : Heat sensing portion of sensor, outside diameter of mount R 1/8 b : Amp c : Connector (power source end) d : Connector (sensor end) Output voltage characteristics (ambient temperature: 20 C) Reference value
Detection temperature (C) Output voltage (V) 50 100 400 700 800
1.191
1.397
2.626
3.899
4.316
Function The exhaust temperature sensor is a thermoelectric type temperature sensor. It is installed to the turbocharger inlet port and outputs the exhaust temperature data to the VHMS controller.
AMBIENT TEMPERATURE SENSOR

Specifications 1. Electricity consumption 2. Pressure resistance : Max. 0.5 mW : 0.98 MPa {10 kg/cm2} 3. Detected temperature range (surrounding) : --30 to 120C 4. Retention temperature range: --30 to 140C 5. Performance table below
Detection temperature (C) Resistance (kz) --20 --10 0 10 20 50
30.32 18.58 11.74 7.623 5.077 1.712
a : Heat sensing portion of sensor, diameter of mount 16 x 1.5 Function The ambient temperature sensor inputs the ambient temperature to the VHMS controller as a change in the resistance of the thermistor.
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HD465-7, HD605-7
COMMUNIVSTIONS (ORB ORBCOMM) CONTROLLER/ANTENNA
COMMUNICATIONS (ORB ORBCOMM) CONTROLLER/ANTENNA

CONTROLLER
Specifications 1. Power supply voltage : DC12V DC30V 2. Size : W306 x D152 x H52 (mm) Installation location Install under assistant's seat. Connector portion CN1A (ORB-A) : AMP070-14 CN1B (ORB-B) : AMP070-10 CN2 : Communications antenna cable connector
ANTENNA
Specifications 1. Type : Helical whip antenna (1) 2. Impedance : 50 3. Input terminal : M-P type 4. Length : 165 20 mm a : Communications antenna mount Installation location Install pole at right front of machine and set antenna on top of it. Function The antenna transmits the data collected and accumulated by the VHMS controller through the communications satellite to the computer center.
HD465-7, HD605-7
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PAYLOAD METER
PAYLOAD METER (HAVING VHMS)

SYSTEM CONFIGURATION
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HD465-7, HD605-7
PAYLOAD METER
Outline A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the outside indicator lamps. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading. The operation data, including the load mass of each transportation cycle, can be saved in the internal memory and downloaded with special software (if equipped). As the special software, the download software for Payload meter (card type) set for HD465/ 605-5 can be used as it is. The hauled load mass can be input by the following alternative 2 methods. (1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). (2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area (New method). The VHMS controller executes the functions of the payload meter and saves the data of each transportation cycle. It displays, sets, and operates various items through the machine monitor and network. When the payload meter is installed for the first time or the VHMS controller is replaced, the necessary items of the VHMS controller must be set again. Payload meter (card type) set for HD465/6055 can be installed for a user who needs a memory card. If it is installed, however, have the machine monitor and VHMS controller recognize that it will execute the functions of the payload meter, by using rotary switch 2 of the transmission controller and VHMS initial setting tool. For setting procedure, see TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and "Replacing Parts".
The payload meter (having VHMS) cannot be installed to a dump truck which is not equipped with the VHMS controller or which is equipped with the VHMS controller and payload meter (card type).
HD465-7, HD605-7
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PAYLOAD METER
ELECTRIC CIRCUIT DIAGRAM

See TROUBLESHOOTING, Troubleshooting of VHMS controller system (VHMS mode). Principle of measurement 1. Outline 2. Measurement of mass when empty (Calibration) For measurement of mass when empty, see Payload meter II (card type). 3. Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose, set the gearshift lever in the "N" position, set the dump control lever in the "FLOAT" position, turn the parking brake ON, and release the retarder brake and foot brake on a ground where the longitudinal inclination of the dump truck is 5 and the lateral inclination is 2. 4. Correction on slope If the dump truck is loaded on a slope, the measured mass is different from the mass measured on a level ground. To solve this problem, the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. (Correction range of inclination angle: 5) 5. Sensing of distance and travel speed The distance and travel speed are obtained from the signals of the travel signal sensor of the dump truck and the travel speed correction information. a Travel signal sensor: Transmission output shaft speed sensor
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HD465-7, HD605-7
PAYLOAD METER
INITIAL SETTING OF PAYLOAD METER

In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to the following table. 1. When the payload meter (having VHMS) or payload meter II (card type) is installed for the first time 2. When the payload meter (having VHMS) or payload meter II (card type) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller is changed
Set position of rotary switch 2 (SW2) of transmission controller (*1) F B 9 B F HD465 or HD605 7 Setting with VHMS initial setting tool (*2) Date Time Time difference Summer time
Setting of payload meter
VHMS controller
PLM-II (card type)
Model
Serial No.
Variation code
Payload meter function is not installed Payload meter function is installed VHMS PLM PLM (Without VHMS)
Not installed Installed Installed Installed Not installed
Not installed Not installed Installed Installed
ST PV P2
Payload meter function is installed
Set properly
(*1) See "TESTING AND ADJUSTING, Adjusting transmission controller". (*2) See "TESTING AND ADJUSTING, Setting up VHMS controller. When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. Wrong setting of rotary switch 2 (SW2) of transmission controller 2. While the payload meter (having VHMS) is not set, there are the menus related to the payload meter on the machine monitor. Wrong setting of rotary switch 2 (SW2) of transmission controller 3. While the payload meter (having VHMS) is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. Wrong setting of the model and serial No. with the VHMS initial setting tool. HD465-7, HD605-7 4. The storage place of the data file made by the download software is not found. Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. Wrong setting of the date and time with the VHMS initial setting tool.
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PAYLOAD METER
BASIC FUNCTIONS OF PAYLOAD METER

For details, see Operation and Maintenance Manual.
7. Setting of OFFSET range This function is used to adjust the calculated load mass by a set amount. 8. Selection of method of entering saved load mass This function is used to select either of the following methods of entering the hauled load mass. 1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). 2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area.
VARIOUS SETTING FUNCTIONS (SERVICE FUNCTIONS)

1. Setting of travel distance to recognize completion of loading When the dump truck travels 160 m from the loading area, the payload meter judges that the loading operation is finished. If the dump truck is unloaded before it travels 160 m, the payload meter does not judge that the dump truck is unloaded and the cycle data is not completed at this time. This function is used to change the travel distance to recognize completion of loading when the distance between the loading area and dump area is very short. 2. Correction of calculation of load mass If the load mass indicated by the payload meter is different from that indicated by the user's load meter, measure the operating mass (when the truck is empty) and gross truck mass (when the truck is loaded with the rated load mass) with the user's load meter, then correct the relation table of the suspension pressure and load mass forcibly with the measured masses and this function. 3. Correction of level of inclination sensor This function is used to correct the level of the inclination sensor. 4. Setting of criterion of maximum travel speed This function is used to set a criterion of the maximum travel speed for the machine control system. 5. Setting of load mass to recognize start of loading The payload meter recognizes that loading is completed when the load mass changes by certain amount. This function is used to change that amount. Since an easy change can cause wrong recognition of loading, verify the machine condition thoroughly when changing. 6. Setting of indication range of outside indicator lamp This function is used to change the indication range of the outside indicator lamp. The condition for turning on the red lamp cannot be changed. If it is changed, the red lamp cannot warn of overloading.
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HD465-7, HD605-7
PAYLOAD METER
OPERATING METHOD
Select "PLM" in Service Mode 1 on the machine monitor. For method of selection, see TESTING AND ADJUSTING, "Special functions of machine monitor (EMMS)".
HD465-7, HD605-7
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PAYLOAD METER
1. Setting of travel distance to recognize completion of loading
Input a travel distance to recognize completion of loading by pressing the following buttons. The setting range is 0 255 m (0.0 0.158 miles). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Stop inputting number. If the set value is too small, the system may recognize that loading is completed while the dump truck is still being loaded.
2. Correction of calculation of payload Since this function affects the accuracy directly, execute the following procedure securely. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. Accordingly, secure a road for this purpose. The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment. Accordingly, perform the following procedure very carefully. This function is used to match the calculation result to the indication of the load meter to be used. It does not always heighten the absolute accuracy. 1) Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper, etc.) 2) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. i) Select "EMPTY WEIGHT".
[>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". [ ] button: Enter the selection. [ ] button: Return to the previous screen. If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected. Check the unit of the input value. The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC): metric ton (SHORT): short ton
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ii) Check that measurement of the weight of the empty dump truck has been completed.
iv) Check the input value.
] button: Check that measurement has been completed and go to the next step. [ ] button: Return to the previous screen. iii) Input the measured weight of the empty dump truck.
[>] button: Select "YES". [<] button: Select "NO". [ ] button: Enter. v) Move the dump truck to a place where you can drive it for about 3 minutes.
[>]
button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. Inputtable range HD465-7: 43.6 [t] (Operating weight 13%) (metric ton) HD605-7: 46.8 [t] (Operating weight 13%) (metric ton)
] button: After getting ready for drive, press this button and start driving the dump truck. [ ] button: Return to the screen for inputting values. Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight.
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vi) Display the progress of measurement.
i)
Select "LOADED WEIGHT". For the method of displaying the following screen, see the steps up to the above step.
] button: Stop measurement and return to the previous screen. As measurement is executed, the number of [ ] increases. When measurement is finished, the next screen appears automatically. 3) Load the dump truck to measure the weight of the fully loaded dump truck.
[>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". [ ] button: Enter the selection. [ ] button: Return to the previous screen. If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected. Check the unit of the input value. The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC): metric ton (SHORT): short ton ii) Check that measurement of the weight of the fully loaded dump truck has been completed.
] button: Return to the menu screen. When loading is started, the menu screen appears automatically. When indicating the current load for reference while the dump truck is being loaded, go out of "Service mode 1" temporarily and return to "Display of load/integrated odometer". On this screen, you can check the current load. 4) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper, etc.) 5) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes.
] button: Check that measurement has been completed and go to the next step. ] button: Return to the previous screen.
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iii) Input the measured weight of the fully loaded dump truck.
v) Move the dump truck to a place where you can drive it for about 3 minutes.
button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. Inputtable range HD465-7: A1 (A1 x 0.25) (metric ton) However, A1 = {43.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 (A2 x 0.25) (metric ton) However, A2 = {46.8 [t] (Operating weight) + 63 [t] (Load capacity)} iv) Check the input value.
[>]
] button: After getting ready for drive, press this button and start driving the dump truck. [ ] button: Return to the screen for inputting values. Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. vi) Display the progress of measurement (Fig. 9).
] button: Stop measurement and return to the previous screen. As measurement is executed, the number of [ ] increases. When measurement is finished, the next screen appears automatically.
[<] button: Select "YES". [>] button: Select "NO". [ ] button: Enter.
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6) Dump the load in the dump area.
3. Correction of level of inclination sensor 1) Move the dump truck to a level place. 2) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. i) Enter value of (F).
] button: Return to the menu screen. If the load is dumped with the dump lever, the menu screen appears automatically. If the load is dumped normally, correction is finished. ] button: Enter the flashing value. ] button: Return to the menu screen. The current standard level value is displayed on the upper line. The clinometer value (F) at the current position flashes. Enter it when it is stabilized. ii) Turn the dump truck 180 degrees (Stop it in the opposite direction). iii) Enter value of (R). [ [
[ [
] button: Enter the flashing value. ] button: Return to the menu screen. The current standard level value is displayed on the upper line. The clinometer value at the current position flashes. Enter it when it is stabilized.
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iv) Enter the standard level value.
4. Setting of criterion of maximum travel speed
Input a criterion of the maximum travel speed by pressing the following buttons. [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Stop inputting number. The setting range is 0 99 km/h (0 62 MPH). (Default: 99 km/h)
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5. Setting of payload to recognize start of loading
6. Setting of indication range of outside indicator lamps
Input a payload to recognize start of loading by pressing the following buttons. [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Stop inputting number. The setting range is 0 25.5%. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below. If the value is reduced, start of loading may be recognized wrongly. If the value is increased and a loader having a small-capacity bucket is used, the forecast function of the outside indicator lamps and the MMS communication may not operate normally.
Input an indication range of the outside indicator lamps by pressing the following buttons. [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Stop inputting number. The setting range is 0 130% of the load capacity. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp), however.
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7. Setting of OFFSET range
8. Selection of method of entering saved payload i) Select the method of entering the saved payload.
Input an offset range by pressing the following buttons. [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Stop inputting number. The setting range is - 5.0 +5.0 [t]. Check the unit of the input value on the previous menu screen. The unit is indicated in the ( ) on the right side of the input value [t]. (METRIC): metric ton (SHORT): short ton
[>], [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped. [ ] button: Enter the selected method. [ ] button: Return to the menu screen. ii) Enter the selected method.
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PAYLOAD METER
Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the valve installed to the suspension and remove only pressure sensor (1). When removing or installing pressure sensor (1), be careful not to let valve (2) rotate. When removing pressure sensor (1), the action of valve core (3) prevents the suspension pressure from going down.
The output characteristics of the sensor are as shown in the diagram on the right.
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PAYLOAD METER
Clinometer To carry out compensation on slopes, the clinometer measures the tilt angle of the chassis in the front-torear direction.
The output characteristics of the clinometer are as shown in the diagram on the right.
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FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING
The following 2 functions of communicating with external devices are installed. They use the RS232C communication port which is installed to download the data of the payload meter. 1. Automatic transmission When dumping is finished, the data of the concerned cycle are transmitted automatically. The data saved in the payload meter can be made by accumulating the above cycle data with the system on the user side. 2. MMS communication If the mass of a bucketful is recognized, the load mass at that time is transmitted automatically. If the final load mass (hauled load mass of the concerned cycle) is entered, its value is transmitted automatically. Upon receiving a request command, the load mass is transmitted in real time. RS232C is used for only the selected one of data downloading, automatic transmission, and MMS communication. Specifications of RS232C connection Baud rate: 9600 bps Data length: 8 bits Stop bit: 2 bits Parity: Not applied Flow control: Not executed
Connection of RS232C (communication line) (3-wire method)
Selecting wiring harness for downloading/automatic transmission/MMS communication
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Distinction of communication control codes The transmitting side transmits data as explained below so that the data in a communication from beginning with STX and finishing with EXT and BCC will have permeability. 1) If there is a code which is the same as STX or ETX in the data area of the communication frame, DLE (10h) is inserted just before that code. 2) If there is a code which is the same as DLE in the data area of the communication frame, DLE (10h) is inserted just before that code. 3) Calculation of BCC XOR (Exclusive-or) is checked in order from STX at the head of the frame to ETX just before BCC, including inserted DLE. When one of 02h (STX), 03h (ETX), and 10h (DLE) is included in the data Original frame
STX (02h) STX (02h) ETX (03h) BCC
Transmitted frame
STX (02h) DLE (10h) STX (02h) ETX (03h) BCC
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Automatic transmission (a) Timing of transmission The operation data of the concerned cycle are transmitted automatically when the concerned cycle data are entered (when dumping is finished). (b) Contents of communication Format (VHMS controller External device)
STX (02h) [1] ETX (03h) BCC
[1]: Cycle data {39 bytes including header (ASCII L)}

Item Header "L" Unused Month Day Time, hour Time, minute Truck ID Open ID Load mass Empty travel time Empty travel distance Empty max. travel speed Empty ave. travel speed Empty stoppage time Stoppage time for loading Loaded travel time Loaded travel distance Loaded max. travel speed Loaded ave. travel speed Loaded stoppage time Dumping time Limited speed Cycle warning code Unused Unused Unused Unused Unused Unused Unused Unused MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) Time Time Unit ASCI1 Integer Month (BCD) Day (BCD) Hour (BCD) Minute (BCD) Integer Integer MIN (10-time value) km (10-time value) km/h km/h MIN (10-time value) MIN (10-time value) MIN (10-time value) km (10-time value) km/h km/h MIN (10-time value) MIN (10-time value) km/h 0 200 0 200 0 6553.5 0 25.5 0 255 0 255 0 6553.5 0 6553.5 0 6553.5 0 25.5 0 255 0 255 0 6553.5 0 25.5 0 99 0 FFFF (HEX) 0 4.0 0 4.0 0 4.0 0 4.0 0 4.0 0 4.0 0 255 0 255 0 23 expression 1 65535 Range Number of byte 1 2 1 1 1 1 1 1 2 2 1 1 1 2 2 2 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) Remarks L (Fixed) 0 (Fixed)
Metric ton (10-time value) 0 6553.5
[BCC]: EX-OR of each bit from STX to ETX Answer (External device
STX (02h) NAK (15h)
VHMS controller)
ETX (03h) BCC
31H (ASCII 1)
Action that VHMS controller takes when answer is abnormal If "NAK" is returned, the VHMS controller transmits up to 2 more times. If "NAK" is still returned, the VHMS controller stops transmission.
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PAYLOAD METER
MMS communication Transmission of unit distinction setting (a) Timing of transmission After the VHMS controller is started by turning the key to the ON position, it transmits the unit distinction setting information automatically. (b) Contents of communication Format (VHMS controller )
STX (02h) [1] [2] ETX (03h) BCC
[1]: K (ASCII) fixed [2]: 02 (h) fixed (Unit classification [HEX]) The unit classification is the same as one used for PLM2. It is fixed to 02 (h) in the VHMS controller. [BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or
STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC
Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of load mass, estimated load mass, and suspension pressure (a) Timing of transmission When mass of 1 bucketful is recognized.
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PAYLOAD METER
(b) Contents of communication Format (VHMS controller)

STX (02h) [1] [2] [3] [4] [5] [6] ETX (03h) BCC
[1]: M (ASCII) fixed [2]: 4 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) [5]: Estimated load mass (C) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) [6]: (B) Calculated suspension pressure [HEX] [8 BYTES] From head
Signal name P FL P FR P RL P RR Position (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) Name Front left suspension pressure (kg/cm2) Front right suspension pressure (kg/cm2) Rear left suspension pressure (kg/cm2) Rear right suspension pressure (kg/cm2) HEX [10-time value] 0 6553.5 [10-time value] 0 6553.5 [10-time value] 0 6553.5 [10-time value] 0 6553.5
[BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or
Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of final load mass (a) Timing of transmission When the concerned cycle data are entered (When dumping is finished), the final load mass (= the load mass to be saved as the hauled load mass of the concerned cycle in the memory) is transmitted automatically. (b) Contents of communication Format (VHMS controller)
STX (02h) [1] [2] ETX (03h) BCC
[1]: P (ASCII) fixed [2]: Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) Order: Lower position upper position from the head byte of [2] [BCC]: EX-OR of each bit from STX to ETX Answer (
STX (02h)
VHMS controller)
ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or
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Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of real-time data (a) Outline of communication procedure 1) The VHMS controller receives a request for the real-time data from MMS. 2) After receiving the request for the real-time data, the VHMS controller transmits the real-time data at intervals of 0.2 seconds. 3) When the VHMS controller receives a request for finishing transmission of the real-time data, it finishes transmission of the real-time data. When the key is turned to the OFF position, transmission of the real-time data is finished, too. (b) Contents of communication 1) Request for real-time data ( VHMS controller) Format
STX (02h) [1] [2] ETX (03h) BCC
[1]: M (ASCII) fixed [2]: A (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller ) Transmission of the real-time data from the VHMS controller is used as a substitute for the answer.
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2) Transmission of real-time data (VHMS controller Format (VHMS controller )

STX (02h) [1] [2] [3] [4] ETX (03h) BCC
[1]: M (ASCII) fixed [2]: 2 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Real-time data (17 BYTES) From head
Signal name P FL P FR P RL P RR INC PAYLD SP DIG STST ANA 1 ANA 2 VEH STAT Position (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) Name Front left suspension pressure (kg/cm2) Front right suspension pressure (kg/ cm2) Rear left suspension pressure (kg/cm2) Rear right suspension pressure (kg/cm2) Inclination angle (degree) Real-time load mass (Metric ton) (Current) Travel speed (km/h) Status of digital signals Unused Unused Status of dump truck HEX [10-time value] 0 6553.5 [10-time value] 0 6553.5 [10-time value] 0 6553.5 [10-time value] 0 6553.5 [Complement of 2 of 100-time value] [10-time value, to 1 decimal place) 0 99 See (*1) 0 0 See (*2)
(*1) Status of digital signals [HEX] bit 0: N signal1: N (OPEN) 0: Other than N (GND) bit 1: BODY FLOAT signal 1: FLOAT (OPEN) 0: Other than FLOAT N (GND) bit 2: Unused bit 3: Unused bit 4: Unused bit 5: Unused bit 6: Unused bit 7: Unused (*2) Status of dump truck [HEX] 00 (h): Engine stopped 01 (h): Empty and stopped 02 (h): Empty and traveling 03 (h): Loading 04 (h): Loaded and traveling 05 (h): Loaded and stopped 06 (h): Unloading [BCC]: EX-OR of each bit from STX to ETX
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Answer (
STX (02h)
VHMS controller)
ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
Action that VHMS controller takes when answer is abnormal Even if "NAK" is returned or any of "ACK", "NAK", and a request for finishing RTM is not returned in RTM transmission timing, the VHMS controller transmits the real-time data normally after 0.2 seconds. If this condition is repeated 10 times, the VHMS controller stops transmission. 3) Request for finishing transmission of real-time data ( Format
STX (02h) [1] [2] ETX (03h) BCC
VHMS controller)
[1]: Q (ASCII) fixed [2]: 2 (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller
STX (02h) ACK (06h)
ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
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20 TESTING AND ADJUSTING

STANDARD VALUE TABLE Standard value table for engine related parts . 20- 2 Standard value table for chassis ..................... 20- 3 TESTING AND ADJUSTING........................... 20-101 TROUBLESHOOTING .................................... 20-301
a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 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.
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TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Model Engine Item Measurement conditions Power mode High idle Economy mode Stationary mode (*1) Engine Speed Low idle Lo Power mode Rated speed Economy mode Boost pressure Hi power mode Torque convertor stall Hi power mode Torque convertor stall At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature) Compression pressure (SAE30 oil) Blow-by pressure Intake valve mm Exhaust valve Oil temperature: 40 60C (Engine speed: 210 250 rpm) MPa {kg/cm2} 0.62 Min. 2.9 {30} Max. 5.4 {550} Min. 1.96 {20} Max. 8.8 {900} # 1, 2, 3 C # 4, 5, 6 Bosch index Max. 670 Max. 3.5 Max. 1.0 0.32 Max. 700 Max. 6.0 Max. 2.5 kPa {mmHg} 1,900 50 Min. 106.6 {Min. 800} Max. 670 1,900 50 Min. 93.3 {Min. 700} Max. 700 750 50 2,000 50 750 50 2,000 50 Hi rpm Unit HD465-7 Serial No.: 7001 7483 HD605-7 Serial No.: 7001 7181 SAA6D170E-3 Standard value 2,270 50 2,200 50 2,100
+0 100
Permissible value 2,270 50 2,200 50 2,100

+0 100
945 50
945 50
Exhaust temperature
(Coolant temperature: Operating range) kPa Power mode {mmH2O} Torque convertor stall (Coolant temperature: Operating range) At high idle (SAE30)
Oil pressure
At high idle (SAE10W) At low idle (SAE30) At low idle (SAE10W)
MPa {kg/cm2}
0.392 0.539 {4.0 5.5} 0.343 0.539 {3.5 5.5} Min. 0.118 {1.2} Min. 0.098 {1.0}
Min. 0.206 {2.1} Min. 0.177 {1.8} Min. 0.080 {0.8} Min. 0.069 {0.7} 120 15
Oil temperature Belt tension (Alternator)
Whole speed range (Inside oil pan) Deflection when pressed with finger force of approx. 58.8 N {6 kg}
C mm
90 110 15
*1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position. When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" position.
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HD465-7, HD605-7
STANDARD VALUE TABLE FOR CHASSIS

Component Item Measurement conditions Engine coolant temperature: Within operating range Transmission oil temperature: 60 80C Machine unloaded Travel resistance: 3.3 % km/h Unit Standard value Standard tires 11.5 5 % 16.0 5 % 21.5 5 % 29.5 5 % 39.0 5 % 52.5 5 % 70.0 5 % 12.0 5 % Engine coolant temperature: Within operating range Transmission oil temperature: 60 80C Hydraulic oil temperature: 45 55C Braking mode refers to when the accelerator is OFF or the rear brake is ON. 2,100 50 1,400 50 Permissible value Standard tires 11.5 5 % 16.0 5 % 21.5 5 % 29.5 5 % 39.0 5 % 52.5 5 % 70.0 5 % 12.0 5 % 2,100 50 1,400 50
F1 F2 Performance F3 Travel speed F4 F5 F6 F7 R Shift up High power mode Shift down Shift up Economy mode Shift down Shift up Shift down
Automatic shift control
1,325 35 1,325 35 (F2 o F1 only) (F2 o F1 only) 2,000 50 1,300 50 2,000 50 1,300 50
1,250 50 1,250 50 (F2 o F1 only) (F2 o F1 only) 2,450 50 1,550 50 *1 *2 2,450 50 1,550 50 *1 *2
Braking mode Auto lock-up Set Reset
Engine speed
rpm
Overrun prevention
Set
2,600 10
2,600 10
Reset
2,350 10
2,350 10
Down-shift inhibitor Transmission oil temperature: 85 110C Hydraulic oil temperature: 45 55C Engine coolant temperature: Within operating range
1,325 35 1,325 35 (F2 o F1 only) (F2 o F1 only) Power mode 1,910100 1,910 100
Torque converter
Economy mode
Engine speed at torque converter stall
1,910100
1,910 100
*1. Torque converter speed ratio is min. 0.85 at min. 1,500 rpm or min. 1,300 rpm *2. F3 F7: 1,050 50 F1, F2 : 1,100 50
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Component Accelerator pedal
Item Starting to depress Operating force Fully Starting to depress i o fully
Measurement conditions Operating effort at a point 150 mm from pedal fulcrum
Unit
Standard value 22.5 4.9 {2.3 0.5}
Permissible value 22.5 4.9 {2.3 0.5}

+ 2.0 42.1 7.8 + 0.3 0.8
N {kg}
2.0 42.1 + 7.8
{4.3 Travel at a point 150 mm from pedal fulcrum At center of lever knob mm N {kg}
+ 0.3 0.8
{4.3
Travel
45 5 21.6 3.9 {2.2 0.4}
45 5 Max. 29.4{3}
Operating force Transmission shift lever RN ND D5 Travel 54 43 3L
mm
24.5 1
24.5 2
At engine speed 2,000 rpm Inlet oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm Torque converter Outlet oil pressure Oil temperature: 75 85C Lock-up oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm Main relief oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) H, 4th clutch Transmission L clutch Control valve set pressure 3rd clutch 2nd clutch 1st clutch MPa {kg/cm2} Oil temperature: 60 80C Engine: at rated speed MPa {kg/cm2}
0.74 0.05 {7.5 0.5} 0.88 0.05 {8.9 0.5} 0.17 0.05 {1.7 0.5} 0.59 0.05 {6.0 0.5} 0.71 0.05 {7.2 0.5} 0.15 0.05 {1.5 0.5} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 3.68 0.15 {37.5 1.5} 3.77 0.15 {38.5 1.5} 3.33 0.15 {34 1.5} 1.67 0.2 {17 2} 1.82 0.2 {18.5 2} 1.77 0.2 {18 2} 3.33 0.2 {34 2} 3.58 0.2 {36.5 2}
0.74 0.05 {7.5 0.5} 0.88 0.05 {8.9 0.5} 0.17 0.05 {1.7 0.5} 0.59 0.05 {6.0 0.5} 0.71 0.05 {7.2 0.5} 0.15 0.05 {1.5 0.5} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 3.68 0.15 {37.5 1.5} 3.77 0.15 {38.5 1.5} 3.33 0.15 {34 1.5} 1.67 0.2 {17 2} 1.82 0.2 {18.5 2} 1.77 0.2 {18 2} 3.33 0.2 {34 2} 3.58 0.2 {36.5 2}
20-4
(10)
HD465-7, HD605-7
Component
Item Oil temperature: 60 80C (When using EO10-CD) or Oil temperature: 80 100C (When using EO30-CD)
24.00-35-36PR (Front and rear tires)
Measurement conditions At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value)
Unit
Standard value 0.15 0.05 {1.5 0.5}
Permissible value 0.15 0.05 {1.5 0.5} 0.17 0.05 {1.7 0.5} 0.09 0.05 {0.9 0.5} 0.46 {4.75}
Transmission
Lubricating oil pressure
MPa {kg/cm2}
0.17 0.05 {1.7 0.5} 0.09 0.05 {0.9 0.5} 0.46 {4.75}
Tires (Inflation pressure)
Machine unloaded
Standard tires
MPa {kg/cm2} Tire (If equipped)

24.00-R35 (Front and rear tires)
0.69 {7.0} With 46ton payload F2 Torque converter stall See Brake A On flat road surface When empty mm 220 10 % rpm MPa {kg/cm2} Min. 25 Min. 1,540
0.69 {7.0} Min. 25 Min. 1,540
Parking brake
Braking capacity Starting test Releasing pressure Front
See Brake 249 10 249 10 (*1) 249 20 249 20 (*1) 220 20 204 20 (*1) 3.82 0.39 {39 4} 2.26 0.29 {23 3}
Suspension cylinder
Installed length Rear B
204 10 (*1) Front Pressure Rear Oil temperature: 60 80C When machine stopped (empty) (If it is impossible when the machine stopped, travel at low speed with engine at low idle) Length at circumference of steering wheel Engine stopped, until tires start to move Lock o lock Left o right Right o left Oil temperature: 45 55C Oil temperature: 60 80C Engine speed: Whole range Lock o lock At high idle (2,270 rpm) At low idle (750 rpm) (Reference value) MPa {kg/cm2} 2.26 0.29 {23 3} 3.82 0.39 {39 4}
Operating force (Turning speed for steering wheel: 30 rpm) Steering wheel
N {kg}
14.7 29.4 {1.5 3.0}
Max. 35.3 {Max. 3.6}
Play
mm
Max. 135
Max. 135
No. of turns Turning time
Turns sec.
3.5 0.3 Max. 4 Max. 4
3.5 0.6 Max. 5 Max. 5 20.1 23.5 {205 240} 20.1 23.5 {205 240}
Steering valve
Relief pressure
MPa {kg/cm2}
20.2 21.1 {206 215} 20.2 21.1 {206 215}
*1. Cylinder with buffer ring
HD465-7, HD605-7
20-5
(10)
Component
Item
Measurement conditions Measure at position a (Position at 150 mm from fulcrum of pedal)
Unit
Standard value
Permissible value
Operating force (Full) Brake pedal
N {kg}
233 29.4 {23.8 3}
234 29.4 {23.8 3}
Travel (Start of depressing o Full)
mm
40 5
40 10
Retarder control lever
Operating force Travel
At point 10 mm from tip of lever
N {kg} deg
5.9 9.8 {0.6 1.0} 0 78

0 2
3.0 14.7 {0.3 1.5} 0 78

0 4
Measure at position a (Position at 150 mm from fulcrum of pedal) Emergency brake pedal
Operating force (Full)
N {kg}
296 29.4 {30.2 3}
296 29.4 {30.2 3}
Service brake braking distance
46 ton payload
Empty
Initial speed: 32 km/h Distance from starting to lose speed to stopping Max. hydraulic pressure Rear: 9.8 MPa {100 kg/cm2} Front: 17.6 MPa {180 kg/cm2} On flat, dry road surface Engine: Stopped When first operated
Max. 22.3 m Max. 17.0 17.6 1.2 {180 12} 9.8 0.7 {100 7} MPa {kg/cm2} 8.7 0.6 {88.5 6.5}
0.98 9.85 + 0.49 10 {100.4 + 5
Max. 22.3
Max. 17.0 17.6 1.2 {180 12} 9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
+ 0.98 9.85 0.49 10 {100.4 + 5 }
Front Brake actuating pressure Brakes Rear (service) Rear (retarder) Parking brake releasing pressure Stopping distance when emergency brake is applied
Engine: Stopped
Carrying 46 ton payload Initial speed: 32 km/h On flat, dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder
Max. 52.1 17.6 1.2 {180 12}
Max. 52.1 17.6 1.2 {180 12} 9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
Brake oil pressure
MPa {kg/cm2}
9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
20-6
(10)
HD465-7, HD605-7
Component
Item Service brake Retarder brake Parking brake
Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually. Measure the engine speed when the truck starts moving
Unit
Standard value
Permissible value
Must not move at 1,870 rpm Must not move at 1,400 rpm rpm Must not move at 1,670 rpm Must not move until torque converter stall speed
Brakes
Emergency brake Front brake (Pad thickness ) Rear brake (Disc wear gauge ) Left side Right side Left side Right side Engine: stopped Center of control lever knob HOLD o RAISE RAISE o HOLD HOLD o FLOAT FLOAT o HOLD FLOAT o LOWER LOWER o FLOAT Travel Engine: stopped Center of control lever knob Oil temperature: 45 55C RAISE o HOLD HOLD o LOWER mm N {kg} mm
19.5 19.5
3.0 3.0
Must be in wear gauge range Must be in wear gauge range Max. 29.4 {Max. 3.0} Max. 35.3 {Max. 3.6}
Must return smoothly when engine is running at high idle Max. 29.4 {Max. 3.0} Max. 29.4 {Max. 3.0} Max. 29.4 {Max. 3.0} Max. 35.3 {Max. 3.6} Max. 35.3 {Max. 3.6} Max. 35.3 {Max. 3.6}
Dump lever
Operating force
Must return smoothly when engine is running at 2,000 rpm 44.8 1.9 44.8 1.9 20.1 21.1 {205 215} 18.6 19.6 {190 200} MPa {kg/cm2} 3.4 0.49 {35 5} 2.6 0.49 {27 5} 11.5 1.5 sec. 10.5 1.5 44.8 1.9 44.8 1.9 19.6 22.6 {200 230} 18.6 19.6 {190 200} 3.4 0.49 {35 5} 2.6 0.49 {27 5} 11.5 1.5
2.0 10.5 + 1.0
Dump valve
At high idle (2,270 rpm) At low idle (750 rpm) (Reference value) At high idle (2,270 rpm)
Relief pressure
Dump EPC valve
Relief pressure ( root pressure)
At low idle (750 rpm) (Reference value) Oil temperature: 45 55C Engine speed: 2,000 rpm Use FLOAT when lowering Oil temperature: 45 55C Set with No. 2 cylinder extended 200 mm Hydraulic drift after 5 minutes
Lifting speed Lowering speed Body Hydraulic drift
mm
Max. 85
170
HD465-7, HD605-7
20-7
(11)

Model Engine Item Measurement conditions Power mode High idle Economy mode Stationary mode (*1) Engine Speed Low idle Lo Power mode Rated speed Economy mode Boost pressure Hi power mode Torque convertor stall Hi power mode Torque convertor stall At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature) Compression pressure (SAE30 oil) Blow-by pressure Intake valve mm Exhaust valve Oil temperature: 40 60C (Engine speed: 210 250 rpm) MPa {kg/cm2} 0.62 Min. 2.9 {30} Max. 5.4 {550} Min. 1.96 {20} Max. 8.8 {900} # 1, 2, 3 C # 4, 5, 6 Bosch index Max. 670 Max. 3.5 Max. 1.0 0.32 Max. 700 Max. 6.0 Max. 2.5 kPa {mmHg} 750 50 2,000 50 1,900 50 (empty) 2,100 50 (loaded) Min. 106.6 {Min. 800} Max. 670 750 50 2,000 50 1,900 50 Min. 93.3 {Min. 700} Max. 700 Hi rpm Unit HD465-7 Serial No.: 7484 and up HD605-7 Serial No.: 7182 and up SAA6D170E-3 Standard value 2,270 50 2,100
+0 50
Permissible value 2,270 50 2,200 50 2,100

+0 100
(empty)
2,270 50 (loaded) 2,100

+0 50
945 50
945 50
Exhaust temperature
(Coolant temperature: Operating range) kPa Power mode {mmH2O} Torque convertor stall (Coolant temperature: Operating range) At high idle (SAE30)
Oil pressure
At high idle (SAE10W) At low idle (SAE30) At low idle (SAE10W)
MPa {kg/cm2}
0.392 0.539 {4.0 5.5} 0.343 0.539 {3.5 5.5} Min. 0.118 {1.2} Min. 0.098 {1.0}
Min. 0.206 {2.1} Min. 0.177 {1.8} Min. 0.080 {0.8} Min. 0.069 {0.7} 120 15
Oil temperature Belt tension (Alternator)
Whole speed range (Inside oil pan) Deflection when pressed with finger force of approx. 58.8 N {6 kg}
C mm
90 110 15
*1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position. When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" position.
20-8
(12)
HD465-7, HD605-7

Component Item F1 F2 F3 Performance Travel speed F4 F5 F6 F7 R High power mode Shift up Shift down Engine coolant temperature: Within operating range Transmission oil temperature: 60 80C Hydraulic oil temperature: 45 55C Measurement conditions Engine coolant temperature: Within operating range Transmission oil temperature: 60 80C Machine unloaded Travel resistance: 3.3 % Standard tires High power mode km/h 39.0 5 % 52.5 5 % 70.0 5 % 12.0 5 % 2,100 50 39.0 5 % 52.5 5 % 70.0 5 % 12.0 5 % 2,100 50 Unit Standard value 11.5 5 % 16.0 5 % 21.5 5 % 29.5 5 % Permissible value 11.5 5 % 16.0 5 % 21.5 5 % 29.5 5 %
1,400 50 1,400 50 1,325 35 1,325 35 (F2 o F1 only) (F2 o F1 only) 1,800/1,935 50 1,800/1,935 50 2,000 50 2,000 50 (F1 o F2 only) (F1 o F2 only) 1,750 50 1,750 50
Full throttle
Empty
Automatic shift control
Half throttle
2,000 50 2,000 50 (F1 o F2 only) (F1 o F2 only) 1,800 50 1,800 50 (F2 o F3 only) (F2 o F3 only)
Engine speed
Economy mode
Shift up
Accelerator OFF (Slow travel) Full throttle
rpm 2,450 50 2,450 50
1,935/2,070 50 1,935/2,070 50 2,100 50 2,100 50 (F1 o F2 only) (F1 o F2 only) 1,750 50 Half throttle 1,750 50
Loaded
Accelerator OFF (Slow travel)
2,450 50
2,450 50
HD465-7, HD605-7
20-9
(12)
Component
Item
Measurement conditions Engine coolant temperature: Within operating range Transmission oil temperature: 60 80C Hydraulic oil temperature: 45 55C
Unit
Standard value 1,300 35
Permissible value 1,300 35
Full throttle
1,250 35 1,250 35 (F2 o F1 only) (F2 o F1 only) 1,200 35 1,200 35
Empty
Half throttle
1,250 35 1,250 35 (F3oF2,F2oF1) (F3oF2,F2oF1) 1,200 35 1,200 35
Accelerator OFF (Slow travel) Automatic shift control Economy mode
Shift down
1,350 35 Full throttle
1,350 35
1,325 35 1,325 35 (F2 o F1 only) (F2 o F1 only) 1,200 35 1,200 35
Loaded
Half throttle
1,250 35 1,250 35 (F3 o F2 only) (F3 o F2 only) 1,325 35 1,325 35 (F2 o F1 only) (F2 o F1 only) 1,200 35 1,200 35
Engine speed
Accelerator OFF (Slow travel)
rpm
Braking mode
Shift up Shift down
2,450 50 1,550 50
Torque converter speed ratio is minimum 0.85 at minimum of 1,500 rpm or 1,300 rpm.
2,450 50 1,550 50
Torque converter speed ratio is minimum 0.85 at minimum of 1,500 rpm or 1,300 rpm.
Auto lock-up
Set
Reset
F3 F7: 1,050 50 F1, F2: 1,100 50 2,600 10 2,350 10 Transmission oil temperature: 85 110C Hydraulic oil temperature: 45 55C Engine coolant temperature: Within operating range 1,910 10 1,800 100 1,875 100
F3 F7: 1,050 50 F1, F2: 1,100 50 2,600 10 2,350 10 1,910 10 1,800 100 1,875 100
Overrun prevention
Set Reset Power mode Engine speed at torque Empty conEconverter omy stall mode Loaded
20-10
(12)
Torque converter
HD465-7, HD605-7
Component Accelerator pedal
Item Starting to depress Fully Starting to depress i o fully
Measurement conditions Operating effort at a point 150 mm from pedal fulcrum
Unit
Standard value 22.5 4.9 {2.3 0.5}

2.0 42.1 + 7.8
Permissible value 22.5 4.9 {2.3 0.5}

+ 2.0 42.1 7.8
Operating force
N {kg}
{4.3 Travel at a point 150 mm from pedal fulcrum At center of lever knob mm N {kg}
+ 0.3 0.8
{4.3
+ 0.3 0.8
Travel
45 5 21.6 3.9 {2.2 0.4}
45 5 Max. 29.4{3}
Operating force Transmission shift lever RN ND Travel D5 54 43 3L
mm
24.5 1
24.5 2
At engine speed 2,000 rpm Inlet oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm Torque converter Outlet oil pressure Oil temperature: 75 85C Lock-up oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm Main relief oil pressure At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value) H, 4th clutch Transmission L clutch Control valve set pressure 3rd clutch 2nd clutch 1st clutch MPa {kg/cm2} Oil temperature: 60 80C Engine: at rated speed MPa {kg/cm2}
0.74 0.05 {7.5 0.5} 0.88 0.05 {8.9 0.5} 0.17 0.05 {1.7 0.5} 0.59 0.05 {6.0 0.5} 0.71 0.05 {7.2 0.5} 0.15 0.05 {1.5 0.5} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 3.68 0.15 {37.5 1.5} 3.77 0.15 {38.5 1.5} 3.33 0.15 {34 1.5} 1.67 0.2 {17 2} 1.82 0.2 {18.5 2} 1.77 0.2 {18 2} 3.33 0.2 {34 2} 3.58 0.2 {36.5 2}
0.74 0.05 {7.5 0.5} 0.88 0.05 {8.9 0.5} 0.17 0.05 {1.7 0.5} 0.59 0.05 {6.0 0.5} 0.71 0.05 {7.2 0.5} 0.15 0.05 {1.5 0.5} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 1.67 0.20 {17 2} 3.68 0.15 {37.5 1.5} 3.77 0.15 {38.5 1.5} 3.33 0.15 {34 1.5} 1.67 0.2 {17 2} 1.82 0.2 {18.5 2} 1.77 0.2 {18 2} 3.33 0.2 {34 2} 3.58 0.2 {36.5 2}
HD465-7, HD605-7
20-11
(12)
Component
Item Oil temperature: 60 80C (When using EO10-CD) or Oil temperature: 80 100C (When using EO30-CD)
24.00-35-36PR (Front and rear tires) 24.00-R35 (Front and rear tires)
Measurement conditions At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value) At low idle (750 rpm) (Reference value)
Unit
Standard value 0.15 0.05 {1.5 0.5}
Permissible value 0.15 0.05 {1.5 0.5} 0.17 0.05 {1.7 0.5} 0.09 0.05 {0.9 0.5} 0.46 {4.75}
Transmission
Lubricating oil pressure
MPa {kg/cm2}
0.17 0.05 {1.7 0.5} 0.09 0.05 {0.9 0.5} 0.46 {4.75}
Tires (Inflation pressure)
Standard tires
Machine unloaded MPa {kg/cm2}
Tire (If equipped)
0.69 {7.0} With 46ton payload F2 Torque converter stall See Brake A On flat road surface When empty mm % rpm MPa {kg/cm2} Min. 25 Min. 1,540
0.69 {7.0} Min. 25 Min. 1,540
Parking brake
Braking capacity Starting test Releasing pressure Front
See Brake 249 10 249 10 (*1) 220 10 204 10 (*1) 3.82 0.39 {39 4} 2.26 0.29 {23 3} 249 20 249 20 (*1) 220 20 204 20 (*1) 3.82 0.39 {39 4} 2.26 0.29 {23 3}
Suspension cylinder
Installed length Rear B
Front Pressure Rear Oil temperature: 60 80C When machine stopped (empty) (If it is impossible when the machine stopped, travel at low speed with engine at low idle) Length at circumference of steering wheel Engine stopped, until tires start to move Lock o lock Left o right Right o left Oil temperature: 45 55C Oil temperature: 60 80C Engine speed: Whole range Lock o lock At high idle (2,270 rpm) At low idle (750 rpm) (Reference value) MPa {kg/cm2}
Operating force (Turning speed for steering wheel: 30 rpm) Steering wheel
N {kg}
14.7 29.4 {1.5 3.0}
Max. 35.3 {Max. 3.6}
Play
mm
Max. 135
Max. 135
No. of turns Turning time
Turns sec.
3.5 0.3 Max. 4 Max. 4
3.5 0.6 Max. 5 Max. 5 20.1 23.5 {205 240} 20.1 23.5 {205 240}
Steering valve
Relief pressure
MPa {kg/cm2}
20.2 21.1 {206 215} 20.2 21.1 {206 215}
*1. Cylinder with buffer ring
20-12
(12)
HD465-7, HD605-7
Component
Item
Measurement conditions Measure at position a (Position at 150 mm from fulcrum of pedal)
Unit
Standard value
Permissible value
Operating force (Full) Brake pedal
N {kg}
233 29.4 {23.8 3}
234 29.4 {23.8 3}
Travel (Start of depressing o Full)
mm
40 5
40 10
Retarder control lever
Operating force Travel
At point 10 mm from tip of lever
N {kg} deg
5.9 9.8 {0.6 1.0} 0 78

0 2
3.0 14.7 {0.3 1.5} 0 78

0 4
Measure at position a (Position at 150 mm from fulcrum of pedal) Emergency brake pedal
Operating force (Full)
N {kg}
296 29.4 {30.2 3}
296 29.4 {30.2 3}
Service brake braking distance
46 ton payload
Empty Front
Initial speed: 32 km/h Distance from starting to lose speed to stopping Max. hydraulic pressure Rear: 9.8 MPa {100 kg/cm2} Front: 17.6 MPa {180 kg/cm2} On flat, dry road surface Engine: Stopped When first operated
Max. 22.3 m Max. 17.0 17.6 1.2 {180 12} 9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
10 {100.4 + 5 0.98 9.85 + 0.49
Max. 22.3
Max. 17.0 17.6 1.2 {180 12} 9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5} }
10 {100.4 + 5 } + 0.98 9.85 0.49
Brake actuating pressure Brakes
Rear (service) Rear (retarder)
MPa {kg/cm2} Engine: Stopped
Parking brake releasing pressure Stopping distance when emergency brake is applied
Carrying 46 ton payload Initial speed: 32 km/h On flat, dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder
Max. 52.1 17.6 1.2 {180 12}
Max. 52.1 17.6 1.2 {180 12} 9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
Brake oil pressure
MPa {kg/cm2}
9.8 0.7 {100 7} 8.7 0.6 {88.5 6.5}
HD465-7, HD605-7
20-13
(12)
Component
Item Service brake Retarder brake Parking brake
Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually. Measure the engine speed when the truck starts moving
Unit
Standard value
Permissible value
Must not move at 1,870 rpm Must not move at 1,400 rpm rpm Must not move at 1,670 rpm Must not move until torque converter stall speed
Brakes
Emergency brake Front brake (Pad thickness ) Rear brake (Disc wear gauge ) Left side Right side Left side Right side Engine: stopped Center of control lever knob HOLD o RAISE RAISE o HOLD HOLD o FLOAT FLOAT o HOLD FLOAT o LOWER LOWER o FLOAT Travel Engine: stopped Center of control lever knob Oil temperature: 45 55C RAISE o HOLD HOLD o LOWER mm N {kg} mm
19.5 19.5
3.0 3.0
Must be in wear gauge range Must be in wear gauge range Max. 29.4 {Max. 3.0} Max. 35.3 {Max. 3.6}
Must return smoothly when engine is running at high idle Max. 29.4 {Max. 3.0} Max. 29.4 {Max. 3.0} Max. 29.4 {Max. 3.0} Max. 35.3 {Max. 3.6} Max. 35.3 {Max. 3.6} Max. 35.3 {Max. 3.6}
Dump lever
Operating force
Must return smoothly when engine is running at 2,000 rpm 44.8 1.9 44.8 1.9 20.1 21.1 {205 215} 18.6 19.6 {190 200} MPa {kg/cm2} 3.4 0.49 {35 5} 2.6 0.49 {27 5} 11.5 1.5 sec. 10.5 1.5 44.8 1.9 44.8 1.9 19.6 22.6 {200 230} 18.6 19.6 {190 200} 3.4 0.49 {35 5} 2.6 0.49 {27 5} 11.5 1.5
2.0 10.5 + 1.0
Dump valve
At high idle (2,270 rpm) At low idle (750 rpm) (Reference value) At high idle (2,270 rpm)
Relief pressure
Dump EPC valve
Relief pressure ( root pressure)
At low idle (750 rpm) (Reference value) Oil temperature: 45 55C Engine speed: 2,000 rpm Use FLOAT when lowering Oil temperature: 45 55C Set with No. 2 cylinder extended 200 mm Hydraulic drift after 5 minutes
Lifting speed Lowering speed Body Hydraulic drift
mm
Max. 85
170
20-14
(12)
HD465-7, HD605-7

Tools for testing, adjusting, and troubleshooting ...................................................................................... 20-101-1 Measuring engine speed............................................................................................................................. 20-102 Adjusting engine speed sensor ................................................................................................................... 20-104 Measuring engine oil pressure .................................................................................................................... 20-105 Measuring air supply pressure (boost pressure)......................................................................................... 20-106 Measuring exhaust temperature ................................................................................................................. 20-108 Measuring blow-by pressure ........................................................................................................................20-110 Troubleshooting of injector...........................................................................................................................20-111 Measuring compression pressure .............................................................................................................20-111-1 Handling equipment in fuel system ..............................................................................................................20-112 Measuring fuel pump outlet port pressure ...................................................................................................20-112 Measuring fuel pump inlet port pressure......................................................................................................20-114 Visual inspection of return fuel .....................................................................................................................20-114 Adjusting injector set load ............................................................................................................................20-115 Bleeding air from fuel circuit.........................................................................................................................20-117 Measuring exhaust color ..............................................................................................................................20-119 Adjusting valve clearance ........................................................................................................................... 20-120 Testing and adjusting alternator belt tension............................................................................................... 20-121 Testing and adjusting, air conditioner compressor belt tension .................................................................. 20-122 Measuring power train oil pressure ............................................................................................................. 20-123 Adjusting transmission speed sensor ......................................................................................................... 20-130 Inspecting brake oil pressure ...................................................................................................................... 20-131 Bleeding air from brake circuit .................................................................................................................... 20-133 Testing wear of front brake pad................................................................................................................... 20-134 Testing wear of rear brake disc ................................................................................................................... 20-135 Method of releasing parking brake in an emergency .................................................................................. 20-136 Testing and adjusting front suspension cylinder ......................................................................................... 20-137 Testing and adjusting inverted type rear suspension cylinder..................................................................... 20-141 Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder).................................... 20-144 Testing and adjusting hydraulic pressure in steering, hoist circuit .............................................................. 20-145 Testing and adjusting oil pressure in dump EPC circuit .............................................................................. 20-148 Air bleeding from steering cylinder.............................................................................................................. 20-149 Procedure for raising dump body in emergency ......................................................................................... 20-150 Adjusting body positioner sensor ................................................................................................................ 20-151 Method for emergency escape when there is failure in electrical system ................................................... 20-152 Adjusting machine monitor (EMMS) ........................................................................................................... 20-156 Adjusting transmission controller ................................................................................................................ 20-160 Initial setting of payload meter ................................................................................................................. 20-160-1 Setting of card-type payload meter after installation or replacement ....................................................... 20-160-2 Special functions of machine monitor (EMMS) ........................................................................................... 20-161 Basic precautions................................................................................................................................... 20-203- 1 Outline.................................................................................................................................................... 20-203- 4 Setting up VHMS controller.................................................................................................................... 20-203- 9 Collection, transmission of data.............................................................................................................. 20-203-11 Inspection and maintenance .................................................................................................................. 20-203-16 Replacing parts ...................................................................................................................................... 20-203-16 Procedure for initial setup of VHMS ....................................................................................................... 20-203-17 Procedure for opening orbcomm service ............................................................................................... 20-203-20 Performing Pm-clinic using manual snapshot (= Quick Pm) ....................................................................... 20-204 Pm-clinic service ......................................................................................................................................... 20-205 HD465-7, HD605-7
20-101
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TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Measurement item Air supply pressure (boost pressure) Wear level of front brake pad Symbol A b Part No. 799-201-2202 566-98-41410 799-101-1502 Coolant, exhaust, and oil temperatures B 6215-11-8170 799-201-1110 799-101-5002 1 Engine oil pressure 2 Steering, hoist oil pressure circuit 790-261-1204 799-401-2320 799-101-5002 1 790-261-1204 799-101-5002 Power train oil pressure C 799-101-5002 1 790-261-1204 Dump EPC oil pressure circuit 3 799-101-5230 799-401-3100 4 02896-11008 799-101-5002 1 Brake oil pressure J 1 799-261-1204 566-35-43561 795-502-1590 795-611-1210 6560-11-8410 6560-11-8310 2 Compression pressure D 6560-11-8210 6560-11-8510 6560-11-7310 795-799-5410 3 795-799-5420 Remover 1 O-ring (3rd) O-ring (4th) Gasket Adapter 6 6 6 1 Injector pull out O-ring Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Nipple Compression gauge Adapter O-ring (TOP) O-ring (2nd) 1 1 1 1 1 6 6 6
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
Part Name Boost gauge KIT Gauge Digital temperature gauge Sensor Wiring harness Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Nipple Adapter
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks -101 200 kPa {-760 1,500 mmHg} Attached tool -99.9 1,299 C Wire length: 490 mm
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} Pressure gauge: 0.98 MPa {10 kg/cm2} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
1 790-261-1204
14 1.5 Face seal type (# 02) (Female: PT 1/8)
18 1.5 (Female: PT 1/8) 0 6.9 MPa {0 70 kg/cm2}
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HD465-7, HD605-7
Measurement item
Symbol C 1
Part No. 799-101-5002 790-261-1204
Part Name Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Cable Tester Adapter Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Adapter Negative pressure gauge Blow-by checker Barring device Thickness gauge Barring device Handy smoke checker Smoke meter Suspension tool Pump assembly Hose Joint Fitting Joint Valve assembly Nipple Stem Joint Regulator assembly Gauge Gauge
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks
Fuel pump outlet pressure
1 K 2 3
795-799-5460 Commercially available 795-799-5550 799-101-5002
C 1 790-261-1204 Fuel pump inlet pressure 1 M 2 Blow-by pressure E 1 Valve clearance F 2 Injector set load F1 1 Exhaust color G 2 1 2 3 4 5 6 Suspension cylinder of adjustment H 7 8 9 795-502-1350 792-610-1000 792-610-1130 792-610-1110 792-610-1120 07020-21732 792-610-1140 792-610-1250 792-610-1260 792-610-1480 795-799-5560 799-201-1504 6162-23-4500 Commercially available 6162-23-4500 799-201-9001 795-799-5550
0 -0.1 MPa {0 -1 kg/cm2} 0 4.9 kPa {0 500 mmH2O}
Bosch index: 0 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24.5 MPa {250 kg/cm2} 9.81 MPa {100 kg/cm2} H7 H13 Charging tool assembly KIT part No. 792-610-1200 H2 H6 Pump assembly KIT part No. 792-610-1100
10 792-610-1640 11 792-610-1400 12 792-610-1430 13 792-610-1440
HD465-7, HD605-7
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Measurement item Troubleshooting of injector At raise of emergency dump body
Symbol J K
Part No. 795-799-5510 792T-491-1110 799-608-3101
Part Name Heat gun Plug Service KIT Discket Harness Lap top type personal computer Push-pull scale Push-pull scale Scale Stopwatch Tester T-adapter assembly Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter T-adapter assembly T-adapter assembly Socket (S) Socket (C) Socket (A)
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For MS-5
Remarks
Initial set up of VHMS controller and, at repair set up L
799-608-3211 799-608-3220
Commercially available 79A-264-0021
OS: Windows 98/2000 0 294 N {0 30 kg} 0 490 N {0 50 kg}
Operating effort
P 79A-264-0091 Commercially available Commercially available Commercially available 799-601-7400 799-601-3450 799-601-7330 799-601-7340 799-601-7360 1 799-601-7370 799-601-7510 799-601-7520
Travel, hydraulic drift Work equipment speed Voltage, resistance
Q R S
For S-16 (White) For M-8 For relay (5 pins) For relay (6 pins) For AMP070-10 For AMP070-12 For AMP070-14 For AMP070-18 For AMP070-20 For DT connector For DT connector (For 24, 40 pin) For speed sensor For fuel temperature sensor For engine coolant temperature sensor For intake temperature sensor
Sensor, wiring harnesses
T 799-601-7530 799-601-7540 799-601-7550 2 3 4 5 6 799-601-9000 799-601-9300 795-799-5520 795-799-5530 795-799-5540
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HD465-7, HD605-7
Measurement item
Symbol 7
Part No. 795-799-5460 795-799-5470 795-799-5480
Part Name Cable (Cummins Part No.: 3824774) Cable (Cummins Part No.: 3824775) Cable (Cummins Part No.: 3824776)
Qty 1 1 1
Remarks Atmosphere pressure sensor Fuel rail pressure sensor Timing rail actuator Fuel pump actuator Fuel rail actuator Engine oil pressure sensor Timing rail pressure sensor Boost pressure sensor Fuel pump pressure sensor
Sensor, wiring harnesses
T 8 9
SKETCH OF SPECIAL TOOL Note: Komatsu cannot accept any responsibility for special tools manufactured according to these drawings. K Plug
HD465-7, HD605-7
20-101-4
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MEASURING ENGINE SPEED

Stop the machine on flat ground, turn the parking brake switch PARKING, and block the tires. a Measure the engine speed under the following condition. Engine coolant temperature: Within operating range Torque converter oil temperature: Within operating range Hydraulic oil temperature: 45 55C 1. Preparation work Turn the starting switch ON and set the machine monitor (EMMS) in the "Monitoring function of service mode 1" to prepare for measurement of the engine speed. a For the operating method, see "Special functions of machine monitor (EMMS)". Monitoring code: 01001 (Engine speed) a The unit of displayed engine speed is 1 rpm.
4. Measuring torque converter stall speed 1) Switch the machine monitor display to the monitoring function of service mode 1 and display the following 2 items at the same time with the monitoring function. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 30100: Torque converter oil temperature a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
2. Measuring low idle speed 1) Set the shift lever N and dump lever in HOLD. 2) Start the engine and set the accelerator pedal in the low idle position and measure the engine speed. 3. Measuring high idle speed 1) Set the shift lever N and dump lever in HOLD. 2) Start the engine and set the accelerator pedal in the high idle position and measure the engine speed.
2) Start the engine and raise the temperature of the hydraulic oil and torque converter oil. a Torque converter oil temperature: 60 80C a Hydraulic oil temperature: 45 55C 3) Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. a If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4) Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter to raise the torque converter oil temperature. 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 operation. 5) When the torque converter oil temperature goes above 90C, run the engine immediately at low idle and return the gearshift lever to the N position. Never operate the gearshift lever with the accelerator pedal depressed. It will cause a big shock and will also lead to a reduction in the service life of the machine.
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6) Run the engine at a mid-range speed, and when the torque converter oil temperature goes down to approx. 80C, run at low idle. a Keep the gearshift lever at the N position. 7) Repeat Steps 3 6 and equalize the oil temperature in the torque converter and transmission. 8) At the same time as repeating Steps 3 and 4, measure the stall speed when the torque converter oil temperature is 80C. a Measure the stall speed 2 or 3 times. a The stall speed may vary according to the following conditions, so always measure the stall speed at the time of delivery. i) Variations according to the engine serial number ii) Variations in engine output due to atmospheric pressure and temperature iii) Variations due to consumption torque of accessories iv) Variations due to features of the torque converter v) Variations according to the method of measuring the stall
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ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

a If the engine speed sensor has been removed and installed or the flywheel has been removed or installed, adjust as follows. 1. Remove engine speed sensor (1). a Before adjusting, remove the engine speed sensor, check that the tip of the sensor is not scratched and that there are no iron particles sticking to it, then install it again.
5. After completing the adjustment, switch the machine monitor to the display of "Monitoring function of service mode 1", and check that the engine speed is displayed normally. a For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). Monitoring code: 01001 (Engine speed)
2. Screw in sensor (1) until the tip of the sensor contacts the tip of the tooth of flywheel ring gear (2). Thread: Loctite hydraulic sealant (No. 21028) 3. Return sensor (1) by the specified angle from that position. a Angle to return: 1/2 3/4 turns a Clearance a of 0.75 1.25 mm is made between the tip of the sensor and the tip of the gear tooth. 4. Fix engine speed sensor (1) and tighten locknut (3). Nut: 33.9 47.5 Nm {3.5 4.8 kgm}
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MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

Special tool list
Symbol 1 C 2 Part No. 799-101-5002 790-261-1204 799-401-2320 Part Name Hydraulic tester Digital type hydraulic tester Hydraulic tester (1.0MPa {10kg/cm2})
(Measuring with measuring instruments) 1. Remove engine oil pressure measurement plug (1).
a Measure the engine oil pressure under the following conditions. Engine oil temperature: Min. 80C Coolant temperature: Within operating range (Measuring with monitor panel) a It is also possible to check the engine oil pressure with the "Monitoring function of service mode 1" of the machine monitor (EMMS). For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). Monitoring code: 37200 (Engine oil pressure) a The engine oil pressure is displayed in units of 1 kPa. a For the method of measurement, see MEASURING WITH MEASURING INSTRUMENTS.
2. Fit nipple [1] of hydraulic tester C1, then connect to hydraulic tester C2.
3. Start the engine, and measure the oil pressure at low idle and high idle. 4. After completing the measurement, remove the measuring equipment and set to the original condition.
HD465-7, HD605-7
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MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

Special tool list
Symbol A Part No. 799-201-2202 Part Name Boost gauge kit Remarks 101 199.9kPa {760 1,500mmHg}
(Measuring with measuring tool) 1. Remove air supply pressure measurement plug (1).
Be careful not to touch any hot parts when removing or installing the measuring tools. a Measure the air supply pressure (boost pressure) under the following conditions. Coolant temperature: Within operating range Torque converter oil temperature: Within operating range Hydraulic oil temperature: 45 55C (Measuring with monitor panel) 1. Change the machine monitor to Service mode 1 and display the following 2 items simultaneously with the monitoring function. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 36500: Boost pressure
2. Fit nipple of boost gauge kit A, then connect gauge.
a For the method of measurement, see MEASURING WITH MEASURING INSTRUMENTS.
3. Run the engine at a mid-range speed or above to bleed the oil from the hose. a Insert the connection of the hose and pressure gauge about half way, repeat the action to open the self-seal portion at the hose end, and bleed the oil. a If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. a If there is oil inside the hose, the gauge will not work, so always bleed the oil.
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4. Run the engine at high idle to stall the torque converter, and measure the air supply pressure (boost pressure). a For details of the procedure for stalling the t o r q u e c o n v e r t e r, s e e M E A S U R I N G TORQUE CONVERTER STALL SPEED. a The air supply pressure (boost pressure) should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained at torque converter stall speed. 5. After completing the measurement, rermove the measuring equipment and set to the original condition.
HD465-7, HD605-7
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MEASURING EXHAUST TEMPERATURE

Special tool list
Symbol Part No. 799-101-1502 B 6215-11-8170 799-201-1110 Part Name Digital temperature gauge Sensor Wiring harness Remarks 99.9 1,299C Wire length: 490 mm
Wait for the temperature of the exhaust pipe to go down before removing or installing the measuring equipment. a Measure the exhaust temperature under the following conditions. Coolant temperature: Within operating range Torque converter oil temperature: Within operating range Hydraulic oil temperature: 45 55C Method using measuring equipment 1. Remove exhaust temperature measurement plug (1). 3. Method of periodic measurement for preventive maintenance service. a To prevent the torque converter from overheating, use the full stall (torque converter stall + hydraulic relief) to stabilize the exhaust temperature, then stall only the torque converter and measure the temperature. 1) Turn the power mode switch to the HIGH POWER position. 2) Start the engine and raise the temperature of the coolant to the operating range. 3) Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4) Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter. At the same time, operate the dump lever to the LOWER position and relieve the oil pressure (full stall). a Continue until the exhaust temperature reaches the standard value of 670C. 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 operation.
2. Install sensor [1], then connect to digital temperature gauge B. a Clamp the wiring harness of the temperature gauge at a suitable place to prevent it from touching any hot part.
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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. a The exhaust temperature will start to go down from the full stall condition, so measure the temperature when it stabilizes. a If the exhaust temperature does not go down but rises, make the set temperature at full stall higher. a After completing the measurement, lower the engine speed to low idle, then return the gearshift lever to the N position. 4. When measuring the maximum value for the exhaust temperature during troubleshooting, do as follows. Carry out actual work and record the maximum exhaust temperature during operation. a Use the PEAK mode of the digital temperature gauge. (Set the temperature gauge to the PEAK mode. The maximum temperature automatically recorded.) a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. Corrected value [C] = Measured value + 2 x (20 ambient temperature) 5. After completing the measurement, remove the measuring equipment and set to the original condition.
Method using monitoring a This method applies only to the VHMS specification machine. 1. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. a Monitoring items (1) Code No. 01001 : Engine speed (2) Code No. 42600 : Exhaust temperature (front)
(1) Code No. 01001 : Engine speed (2) Code No. 42601 : Exhaust temperature (rear)
a For details of the method of measuring, see METHOD USING MEASURING EQUIPMENT.
HD465-7, HD605-7
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MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

Special tool list
Symbol Part No. 799-201-1504 Part Name Remarks Blow-by checker 0 4.9 MPa {0 500 mmH2O}
Method using measuring equipment 1. Install nozzle and hose [1] to blow-by hose (1), then connect to blow-by checker E.
5. After completing the measurement, remove the measuring equipment and set to the original condition.
2. Start the engine and raise the temperature of the coolant to the operating range. 3. Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4. Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter, and measure the blow-by pressure. There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any position other than the D position during the stall operation. a After completing the measurement, run the engine at low idle, then return the gearshift lever to the N position.
Method using monitoring a This method applies only to the VHMS specification machine. 1. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 42800: Blow-by pressure
a For details of the method of measuring, see METHOD USING MEASURING EQUIPMENT.
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HD465-7, HD605-7
TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF INJECTOR
Special tool list
Symbol J Part No. 795-799-5510 Heat gun Part Name
a If the engine output drops or there is any other problem, if there is the possibility of defective combustion due to defective injection by the injector, carry out troubleshooting of injector. 1. Stop the engine and leave it to cool down. a When cooling the engine down, as a guideline, wait for the temperature of the exhaust manifold to cool down to a temperature of "ambient temperature +20C". 2. Make marks a for measurement to the exhaust manifolds of the all cylinders. a Make marks to the same points on the upper side or lower side of the exhaust manifolds of the all cylinders.
6. Adjust the temperature of each cylinder measured 12 minutes after by the compensation value and find out the abnormal cylinder. a Compensation value
Cylinder No.1 Compensa- +20 tion value No.2 +5 No.3 0 No.4 0 No.5 +5 Unit:C No.6 +20
a Method of judgment Add up the temperatures after compensating, then calculate the average temperature. If the temperature of any cylinder is more than 20C lower than the average, judge that the cylinder is abnormal. 1) Measurement and judgment example 1: No.2 cylinder is more than 20C lower than the average value, so judge that No.2 cylinder is abnormal.
Cylinder No.1 Measured 85 value Compensation value 105 Average value No.2 62 67 No.3 79 79 93 No.4 112 112 No.5 89 94 Unit:C No.6 82 102
3. Using the heat gun J, measure the exhaust manifold outlet temperature of each cylinder before starting the engine. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point. 4. Run the engine at low idle. 5. Using the heat gun J, measure the exhaust manifold outlet temperature of each cylinder 3, 6, 9, and 12 minutes after starting the engine. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point.
2) Measurement and judgment example 2: No.3 cylinder is more than 20C lower than the average value, so judge that No.3 cylinder is abnormal.
Cylinder No.1 Measured 86 value Compensa- 106 tion value Average value No.2 96 101 No.3 73 73 99 No.4 91 91 No.5 94 99 Unit:C No.6 103 123
3) Measurement and judgment example 3: No cylinder is more than 20C lower than the average value, so judge that all cylinders are normal.
Cylinder No.1 Measured 70 value Compensa- 90 tion value Average value No.2 88 93 No.3 88 88 91 No.4 93 93 No.5 86 91 Unit:C No.6 72 92
HD465-7, HD605-7
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MEASURING COMPRESSION PRESSURE

a Special tools list
Symbol 1 Part No. 795-502-1590 795-611-1210 6560-11-8410 2 6560-11-8310 6560-11-8210 6560-11-8510 6560-11-7310 3 795-799-5410 795-799-5420 Part Name Compression gauge Adapter O-ring (Top) O-ring (2nd) O-ring (3rd) O-ring (4th) Gasket Adapter Remover
4. Remove injector push rods (2) and injectors (3). a Using tool D3, pull out each injector (See DISASSEMBLY AND ASSEMBLY).
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 60C). a Since adapter assemblies D2 of the all cylinders should be removed and installed simultaneously for efficiency, prepare 6 sets of them. 1. Open the right side cover and left side cover of the engine. 2. Remove all cylinder head covers. 3. Remove rocker arm assemblies (1) of all the cylinders.
5. Install adapter assemblies D2 to the all cylinders and secure them with the holders. a Install the adapter assemblies with the drain holes in the diagonal direction of the holders. a Secure the adapter assemblies with the injector holders. 3 Holder mounting bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
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6. Install rocker arm assemblies (1) and adjust the valve clearance. 2 Threads and seat of mounting bolt: Engine oil (EO30CD) 3 Mounting bolt: 235.2 254.8 Nm {24 26 kgm}
10. After finishing measurement, remove the measuring instruments and return the removed parts. a Measure the stem length of the injector holder mounting bolt. If it is longer than 80 mm, replace the bolt. 3 Holder mounting bolt: 1st time: 24.5 34.3Nm {2.5 3.5kgm} 2nd time: Tighten by 90 120 2 Threads and seat of holder mounting bolt: Engine oil (EO30CD)
7. Disconnect 2 connectors (4) (POW) and (SIG) of the engine. a After this step, the fuel pump does not supply fuel to the injectors.
2 Threads and seat of rocker arm assembly mounting bolt: Engine oil (EO30CD)
3 Rocker arm assembly mounting bolt: 235.2 254.8 Nm {24 26 kgm} a Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. a Adjust the set load of the injector. For details, see ADJUSTING SET LOAD OF INJECTOR.
3 Cylinder head cover mounting bolt: 9.8 1.0 Nm {1 0.1 kgm}
8. Connect compression gauge D1 to adapter assembly D2 of the cylinder to be measured.
9. Crank the engine with the starting motor and measure the compression pressure. a Read the gauge when its pointer is stabilized.
HD465-7, HD605-7
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HANDLING EQUIPMENT IN FUEL SYSTEM MEASURING FUEL PUMP OUTLET PORT PRESSURE
HANDLING EQUIPMENT IN FUEL SYSTEM

a Precautions for inspection and maintenance of fuel system The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so problems 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. a 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 conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.
MEASURING FUEL PUMP OUTLET PORT PRESSURE

Special tool list
Symbol C 1 1 K 2 3 Part No. 799-101-5002 790-261-1204 795-799-5460 Commercially available 795-799-5550 Part Name Hydraulic tester Digital hydraulic tester Cable Tester Adapter
1. Measuring pressure sensor signal voltage 1) Disconnect connector CN-PMPR (1) of the fuel pump pressure sensor, then connect cable K1 to the male and female ends.
2) Start the engine, switch the machine monitor to the display of "Monitoring function of service mode 1", and prepare to measure the engine speed. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). Monitoring code: 01001 (Engine speed) a The engine speed is displayed in units of 1 rpm.
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MEASURING FUEL PUMP OUTLET PORT PRESSURE
3) Run the engine at low idle and check that the source voltage of the fuel pump pressure sensor is in the following range. a Source voltage of sensor (CN-PMPR connector between (A) (B)): 4.75 5.25 V 4) Run the engine at each speed in the following table and check that the signal voltage of the fuel pump pressure sensor is in the corresponding range shown in the same table. a Signal voltage of sensor (CN-PMPR connector between (C) (D)): Table 1 Engine speed and signal voltage
Engine speed Fuel pump outlet port Signal voltage pressure (Reference) 1.23 0.14 MPa {12.6 1.43 kg/cm2} 1.57 0.14 MPa {16.0 1.43 kg/cm2}
1,000 rpm 1.68 0.21 V 1,300 rpm 3.00 0.21 V
1.78 0.14 MPa 1,500 rpm 3.26 0.21 V {18.15 1.43 kg/cm2}
2. Measuring with pressure gauge (directly) 1) Fit adapter K3 to nipple (2) for measuring the pump outlet port pressure. 2) Install nipple [1] of hydraulic tester C1 to nipple (2) and connect them to hydraulic tester H1.
3) Start the engine, switch the machine monitor to the display of "Monitoring function of service mode 1", and prepare for measuring the engine speed. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR. Monitoring code: 010 (Engine speed) a The engine speed is displayed in units of 1 rpm. 4) Run the engine at the speed shown in Table 1 and check that the pump outlet port pressure is in the range shown in the table 1.
HD465-7, HD605-7
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MEASURING FUEL PUMP INLET PORT PRESSURE VISUAL INSPECTION OF RETURN FUEL
MEASURING FUEL PUMP INLET PORT PRESSURE

Special tool list
Symbol C 1 1 M 2 Part No. 799-101-5002 790-261-1204 795-799-5550 795-799-5560 Part Name Hydraulic tester Digital hydraulic tester Adapter Negative pressure gauge (0 -0.1 MPa{0 -1.02 kg/cm2})
3. Run the engine at a medium speed to bleed the oil from the hose. a Insert the connection of the negative pressure gauge and hose about halfway, repeat the action to open the self-seal portion at the hose end to bleed the oil. a If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. a If there is oil inside the hose, the gauge will not work, so always bleed the oil. 4. Run the engine at full throttle and measure the pump inlet port pressure (See Table 1). Table 1
Fuel filter New Used Fuel pump inlet port pressure Max. 13.60 kPa {Max. 102 mmHg} Max. 27.10 kPa {Max. 203 mmHg}
1. Fit adapter M1 to pump inlet port pressure measuring nipple (1). 2. Fit nipple [1] of hydraulic tester C1 and hose [2] to adapter M1 and connect them to negative pressure gauge M2.
VISUAL INSPECTION OF RETURN FUEL

a The fuel used for control of the timing rail in the fuel circuit and the excessive fuel that is not used injected in the fuel rail are returned from the injector through the fuel cooler to the fuel tank. a If the engine does not revolve normally or fuel consumption is abnormally high, inspect the return fuel according to the following procedure. 1. Disconnect the fuel return hose before the fuel tank. a Plug the hole of the fuel tank. a Keep the return hose open and receive the fuel with an oil pan, etc. 2. Start the engine and check that the fuel flows out of the fuel return hose smoothly. a Fuel spillage (Reference) At low idle: 4 6 /min At high idle: 10 12 /min a If the fuel spillage is extremely low, check the return piping and fuel cooler for clogging.
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ADJUSTING INJECTOR SET LOAD

Special tool list
Symbol F1 Part No. 6162-23-4500 Part Name Barring device
a The cylinder where the injector is adjusted 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 dead center Injector to adjustment 1 2 5 4 3 1 6 5 2 3 4 6
1. Open the engine hood cover. 2. Remove all cylinder head covers (1).
3. Rotate the crankshaft in the normal direction, align [1.6TOP] line a on the damper with pointer (2), and set the No.1 cylinder at compression top dead center. a Remove the flywheel housing cover and install barring device F1 to rotate the crankshaft.
4. Loosen locknut (2) of the injecter to be adjusted and adjustment screw (1) completely, and then tighten the adjustment screw with your fingers. a Check that the socket at the tip of the rocker arm and the ball of the push rod are both fitted securely into the injector and push rod, respectively. 5. Tighten adjustment screw (1), repeat the loosening operation, then tighten finally. Adjustment screw: 1st time : 29.4 34.3 Nm {3.0 3.5 kgm} 2nd time : Loosen fully 3rd time : 29.4 34.3 Nm {3.0 3.5 kgm} 4th time : Loosen fully 5th time : 29.4 34.3 Nm {3.0 3.5 kgm}
a At compression top dead center, the rocker arm of the No.1 cylinder can be moved by hand and amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn.
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6. Hold adjustment screw (1) in position, then tighten locknut (2). Locknut: 205.8 245 Nm {21 25 kgm}
7. After completing the adjustment, set to the original position. Cylinder head mounting bolt : 9.8 1.0 Nm {1 0.1 kgm}
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BLEEDING AIR FROM FUEL CIRCUIT
a If the engine does not start or is difficult to start after the following operations or conditions, bleed the air from the fuel circuit as follows. When starting the engine for the first time After cleaning the fuel tank After adding fuel when the engine has stalled After replacing the fuel filter (only when the air is not bled easily) 1. Check that there is ample fuel in the fuel tank. 2. Remove fuel filter (1), fill it with fuel, then install it again. a Carry out this operation only if the fuel filter has been replaced. a If the fuel filter is not to be replaced, there is danger of dirt getting in, so do not remove the fuel filter.
a Add fuel from the inlet port a (8 places). Portion b is the outlet port after filterinig (clean side), so never add fuel from portion b.
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3. Crank the engine with the starting motor, push air bleed the valve (1), and bleed the air from the vent circuit. a There is no problem with starting even if some air is in the circuit, so if the fuel flows out the bleeding operation is completed. 4. Start the engine and run at low idle. a The injector is an open circuit, so while the engine is running the air remaining in the circuit is released from the injector to the inside of the engine or the fuel tank. a After the engine is started, the engine rotation will be slightly unstable until the air remaining in the circuit is completely bled, so continue to run the engine at low idle until it stabilizes. a If the engine will still not start after the above operation, fill the fuel pump with fuel as follows. 1) Remove air bleeding valve (1). 2) Fill with clean fuel through the hole in the valve until it overflows. a Amount of fuel to add: Approx. 30 cc (reference) 3) Install air bleeding plug (1). Air bleeding plug: 12.7 Nm {1.3 kgm} 4) Crank the engine with the starting motor.
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MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

Special tool list
Symbol G 1 2 Part No. 799-201-9001 795-502-1350 Part Name Handy smoke checker Smoke meter Remarks Bosch index: 0 9
Be careful not to touch any hot parts when removing or installing the measuring tools. When measuring with a handy smoke meter, avoid standing against the exhaust gas and insert the exhaust gas suction port into the exhaust pipe. a When measuring in the field where there is no air or electric power supply, use handy smoke 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. 3) Start the engine and raise the temperature of the coolant to the operating range. 4) Keep the dump body raised and set handy smoke checker G1 to the joint of the exhaust pipe and dump body.
2. Measuring with Smoke Meter G2 1) Keep the dump body raised and insert the probe of smoke meter G2 in the joint of the exhaust pipe and dump body and fix it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose and accelerator switch to smoke meter G2. a Keep the pressure of the air supply below 1.5 MPa (15 kg/cm2). 3) Connect the power cord to the AC socket. a Before connecting the cord, check that the power switch of the smoke meter is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. 5) Turn the power switch of smoke meter G2 ON.
5) Accelerate the engine suddenly, and operate the handle of handy smoke checker G1 while running at high idle to collect the exhaust gas on the filter paper. 6) Remove the filter paper and compare it with the scale supplied to judge the condition.
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ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Special tool list
Symbol 1 F Part No. 6162-23-4500 Commercially available Part Name Barring device Feeler gauge
4. Insert feeler gauge F2 into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw (5). a Insert the feeler gauge and turn the adjustment screw until the clearance is a sliding fit. 5. Hold adjustment screw (5) in position, then tighten locknut (6). Locknut: 57.8 77.4 Nm {5.9 7.9 kgm} a After tightening the locknut, check the valve clearance again.
1. Open the engine hood. 2. Remove all cylinder head covers (1).
3. Rotate the crankshaft in the normal direction, to set the No.1 cylinder at compression top dead center, and align [1.6TOP] line a on the damper with pointer (2). a Use a barring device F1 on the flywheel housing to carry out cranking. a At compression top dead center, the rocker arm of the No.1 cylinder can be moved by hand an amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn.
6. Rotate the crankshaft 120 each time in the normal direction and repeat the procedure in Steps 3 5. You may adjust the valves marked with q when the No. 1 cylinder is at the compression top dead center and adjust the valves marked with Q when the No. 6 cylinder is at the compression top dead center, referring to the following valve arrangement. Firing order: 153624 a 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 original condition. Cylinder head cover mounting bolt: 9.8 1.0Nm {1.0 0.1 kgm}
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HD465-7, HD605-7
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION

Testing Measure deflection a when a point midway between the alternator pulley and idler pulley is pressed with a finger. a Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting a If the deflection is not correct, adjust as follows. 1. Loosen the 2 alternator (1) mounting bolts and 1 lock bolt (2) for the adjustment rod. 2. Loosen locknut (3), then turn adjustment nut (4) to move alternator (1) and adjust the belt tension. 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}
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TESTING AND ADJUSTING, AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING, AIR CONDITIONER COMPRESSOR BELT TENSION

Testing Measure deflection a when a point midway between the air conditioner compressor pulley and idler pulley is pressed with a finger. a Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting a If the deflection is not correct, adjust as follows. 1. Loosen the mounting bolts (2) of air conditioner compressor bracket (1). 2. Loosen locknut (3), then turn adjustment nut (4) to move air conditioner compressor bracket (1) and adjust the belt tension. 3. After completing the adjustment, tighten air conditioner compressor mounting bolts.
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MEASURING POWER TRAIN OIL PRESSURE
Special tool list

Symbol Part No. 799-101-5002 C1 790-261-1204 Part Name Remarks Pressure gauge Analog hydraulic 2.5, 5.9, 39.2, meter 58.8 MPa {25, 60, 400, 600 kg/cm2} Digital hydraulic Pressure gauge 58.8 MPa meter {600 kg/cm2}
a Table of oil pressure measurement port positions and gauges to use

No. 1 2 3 4 5 6 7 8 9 11 Measurement location Main relief pressure Torque converter inlet port pressure Torque converter outlet port pressure Torque converter lock-up clutch pressure Transmission Lo clutch pressure Transmission Hi clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Transmission R clutch pressure Gauge (MPa{kg/cm2}) 5.9{60} 2.45{25} 2.45{25} 5.9{60} 5.9{60} 5.9{60} 5.9{60} 5.9{60} 5.9{60} 5.9{60} 5.9{60} 5.9{60}
10 Transmission 4th clutch pressure 5A- Each clutch pilot pressure 11A
a The transmission lubrication pressure is represented by the torque converter outlet port pressure, so there is no need to measure it.
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Stop the machine on a level ground, turn the parking brake switch PARKING, and put chocks under the tires. Stop the engine and wait until the oil temperature lowers sufficiently before installing and removing the measuring instruments. When measuring the oil pressure while the machine is traveling, secure a wide travel area and take care of the safety around the machine.
Items related to torque converter

2. Measuring torque converter inlet oil pressure Raise the dump body and lock it with the safety 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) Referring to TESTING MAIN RELIEF OIL PRESSURE, check that there is not abnormality. 2) Remove plug (2) and install tool C (2.45 MPa {25 kg/cm2}) (including C1, [1]).
Whole power train

1. Measuring main relief pressure Raise the dump body and lock it with the safety pin. Take care not to "get burned", since the oil temperature is high. When removing and installing a plug or an oil pressure gauge, stop the engine. 1) Raise the transmission oil temperature. a Oil temperature for measurement: 60 80C 2) Remove plug (1) and install tool C (5.88 MPa {60 kg/cm2}) (including C1, [1]).
3) Start the engine and measure the oil pressure at high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.
3) Start the engine and set the gear shift lever in the "N", and then measure the oil pressure at low idle and high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.
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3. Measuring torque converter outlet oil pressure Raise the dump body and lock it with the safety 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) Referring to TESTING MAIN RELIEF OIL PRESSURE, check that there is not abnormality. 2) Remove plug (3) and install tool C (2.45 MPa {25 kg/cm2}) (including C1, [1]).
4. Measuring torque converter lock-up clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (4), (4A) and install the nipple and hoses [1] for measurement.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position L. 7) Release the brake, travel at high idle, and measure the oil pressure when the lock-up pilot lamp lights up. In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.
3) Start the engine and measure the oil pressure at high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.
8) After completing the measurement, remove the measuring equipment and set to the original condition.
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Transmission related a Table of gearshift lever positions, speed ranges, and clutches actuated
Gearshift lever Clutches Speed R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R F1 F2 F3 F4 F5 F6 F7 N R
5. Measuring transmission Lo clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (5), (5A) and install the nipple and hoses [1] for the measurement.
a The mark indicates the speed ranges that are actuated for each position of the gearshift lever. a The mark and mark indicate the clutches that are actuated for each travel speed. a The mark indicates the speed range when measuring the oil pressure for each clutch.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of 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 pressure when traveling at high idle. In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.
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6. Measuring transmission Hi clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (6), (6A) and install the nipple and hoses [1] for the measurement.
7. Measuring transmission 1st clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (7), (7A) and install the nipple and hoses [1] for the measurement.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of 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 3. 7) Release the brake, travel at high idle, and measure the oil pressure when the shift indicator shows "3". In F3, a maximum travel speed of approx. 21.5 km/h is reached, so check carefully that the surrounding area is safe. 8) After completing the measurement, remove the measuring equipment and set to the original condition.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of 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 pressure when traveling at high idle. In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.
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8. Measuring transmission 2nd clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (8), (8A) and install the nipple and hoses [1] for the measurement.
9. Measuring transmission 3rd clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (9), (9A) and install the nipple and hoses [1] for the measurement.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of 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 4. 7) Release the brake, travel at high idle, and measure the oil pressure when the shift indicator shows "4". In F4, a maximum travel speed of approx. 29.5 km/h is reached, so check carefully that the surrounding area is safe.
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10. Measuring transmission 4th clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (10), (10A) and install the nipple and hoses [1] for the measurement.
11. Measuring transmission R clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (11), (11A) and install the nipple and hoses [1] for the measurement.
3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of 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 R. 7) Release the brake and measure the oil pressure when traveling at high idle. In R, a maximum travel speed of approx. 12.0 km/h is reached, so check carefully that the surrounding area is safe.
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ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
a There are 3 speed sensors installed to the transmission. Adjust each sensor as follows. CN3: Input shaft speed sensor CN4: Intermediate shaft speed sensor CN5: Output shaft speed sensor 1. Screw in until the tip of sensor (1) contacts the face or tip of the tooth of gear (2). a Before installing, check that the tip of the sensor is not scratched and that there are no iron particles sticking to the sensor tip. Thread portion: Gasket sealant (LG-5) 2. Turn back sensor (1) 1/2 1 turn from this position. a Adjust clearance a between the tip of the sensor and the tip of the gear tooth to 0.75 1.0 mm.
3. Secure nut (3) with sensor (1). Nut: 49.0 68.6Nm {5 7 kgm}
4. After completing the adjustment, check that the each transmission shaft speed is displayed normally by using the monitoring function of the machine monitor. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
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HD465-7, HD605-7
INSPECTING BRAKE OIL PRESSURE

Special tool list
Symbol Part No. 799-101-5002 C1 790-261-1204 J 566-35-43561 Part Name Remarks Pressure gauge Analog hydraulic 2.5, 5.9, 39.2, meter 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge Digital hydraulic 58.8 MPa meter {600 kg/cm2} Nipple 18 1.5 (female: PT 1/8)
4) Measure the cut-out pressure at high idle. Read the ACC oil pressure (front or rear) when it stops rising at the highest point (Approx. 20.6 MPa {Approx. 210 kg/ cm2}) after the cut-in pressure. (Measuring with diagnosing devices) 1) Stop the engine and remove plug (4) (18, P: 1.5). Connect nipple J and hose [1] and install oil pressure gauge C1 (Oil pressure gauge: 39.2 MPa {400 kg/cm2}).
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 simultaneously with the monitoring function. a Monitoring items (1) Code No. 35500: ACC oil pressure (Front) (2) Code No. 35501: ACC oil pressure (Rear)
2) Start the engine. 3) Measure the cut-in pressure at high idle. i) Press and release the brake pedal repeatedly to lower the oil pressure in the accumulator. ii) Read the lower one of the ACC oil pressures (front or rear) when it starts rising after it reaches the bottom (Approx. 14.2 MPa {Approx. 145 kg/cm2}). a For the method of measurement, see MEASURING WITH MONITOR, 2) 4). (Read the pointer of the oil pressure gauge, however.)
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2. Rear brake operating pressure 1) Remove air bleeder (1) and install tool C1 [Oil pressure gauge: 39.2 MPa {400 kg/ cm2}]. 2) Operate the brake pedal and retarder control lever and measure the oil pressure. a After finishing measurement, bleed air, r eferr ing to BLEE DING A IR FRO M 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 pressure. a After finishing measurement, bleed air, r eferr ing to BLEE DING A IR FRO M BRAKE CIRCUIT on the next page.
4. Front brake operating pressure 1) Remove air bleeder (3) and install tool C1 [Oil pressure gauge: 39.2 MPa {400 kg/ cm2}]. 2) Operate the brake pedal and measure the oil pressure. a After finishing measurement, bleed air, r efe rr ing to B LEEDING AIR FROM BRAKE CIRCUIT on the next page.
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BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE CIRCUIT

a If any brake circuit device was removed and installed or if the transmission and brake cooling oil was replaced, bleed air from the brake circuit according to the following procedure. Stop the machine on a level ground and set chocks under the tires securely. 1. Rear brake a Bleed air from the slack adjuster side first, then bleed air from the wheel brake side. 1) Using a vinyl tube for bleeding air, depress the brake pedal and loosen air bleeder screw (1) or (2) by 3/4 turns. Keep depressing the brake pedal until bubbles do not come out of the bleeder any more. When bubbles do not come out any more, tighten (close) the bleeder and release the pedal. 2) Pull the retarder control lever and loosen air bleeder screw (1) or (2) by 3/4 turns. Keep pulling the retarder control lever until bubbles do not come out of the bleeder any more. When bubbles do not come out any more, tighten (close) the bleeder and release the retarder control lever. 2. Parking brake a Bleed air from the differential top block side first, then bleed air from the wheel brake side. 1) Using a vinyl tube for bleeding air, turn OFF the parking brake switch (release the parking brake) and loosen air bleeder screw (4) by 3/ 4 turns. 2) When bubbles do not come out of the bleeder any more, tighten (close) the bleeder and turn ON the parking brake switch (apply the parking brake). 3) Bleed air from bleeder (5) on the wheel side similarly to step 1) above. a After finishing bleeding air, tighten (close) the bleeder and put the cap. 3. Front brake a Check that the front brake cut switch is turned OFF. 1) Loosen air bleeder (6) by 3/4 turns and bleed air similarly to step 1) for the rear brake.
3) Bleed air from bleeder (3) on the wheel side similarly to step 1) above. a After finishing bleeding air, tighten (close) the bleeder and put the cap.
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TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF FRONT BRAKE PAD

Special tool list
Symbol b Part No. 566-98-41410 Part Name Gauge Remarks Tools on truck
Stop the machine on level ground, apply the parking brake, and put chocks under the tires. 1. Visual check Check visually, and if the pad has reached the wear limit line, replace the pad.
2. Checking with gauge 1) Depress the brake pedal, keep the pad (1) pressed against the disc (2), then insert inspection gauge b into indicator hole d of the caliper (3). 2) If the stepped part of the gauge contacts the mouth of the hole, the pad has reached the wear limit, so replace it. e: Remaining thickness up to wear limit a Replace the pads on the left and right sides at the same time. a The pad wear is not the same for both left and right sides, so check the wear of all pads.
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TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR BRAKE DISC

Stop the machine on level ground, turn the parking brake switch PARKING, and put chocks under the tires. Carry out the inspection when the brake oil temperature is less than 60C. When the disk comes close to the wear limit, carry out the inspection more frequently. Be sure to carry out inspection of the retarder braking performance at the same time. 1. Check that the brakes other than parking brake are not being actuated. 2. Stop the engine. 3. Remove cap nut (1) of the gauge.
6. Install cap nut (1) of the gauge. Cap nut: 19.6 Nm {2.0 kgm}
4. Push in the rod (2) of the gauge until it contacts the piston and judge the amount of wear. a With a new machine, adjust so that inner (deeper) end a of groove D on the rod (2) is aligned with the end face of guide (3). The adjustment position will move out of alignment, so do not loosen locknut (4) of guide (3) except when replacing the disc. a Outer end b of groove D indicates the wear limit for the disc. If it is inside guide (3) totally [If it reaches the end face of guide (3)], the disc has reached the wear limit.
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METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY

a If the parking brake cannot be released because of a trouble in its electric or hydraulic system, release it tentatively according to the following procedure. If the hydraulic system has a trouble, the wheel brake probably does not work normally. Accordingly, be sure to tow the machine at low speed after releasing the parking brake. When releasing the parking brake, stop the machine on a level place and make sure of the safety around it. If it is obliged to release the parking brake on a slope in an emergency, put chocks under the tires securely. When releasing the parking brake, stop the engine. 1. Remove plugs (1) (10 pieces). a Prepare a container to receive the oil flowing out of the plug holes. Tightening torque for plug: 24.5 34.3 Nm {2.5 3.5 kgm}
2. Prepare 10 sets of bolt (2) (01017-51230), washer (3), and nut (4) for releasing the parking brake manually and tighten the bolts alternately and evenly to release the parking brake. a Tighten nuts (4) to pull piston (5) and release the parking brake.
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TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER

Special tool list
Symbol 1 2 3 4 5 6 7 H 8 9 10 11 12 13 Part No. 792-610-1000 792-610-1130 792-610-1110 792-610-1120 07020-21732 792-610-1140 792-610-1250 792-610-1260 792-610-1480 792-610-1640 792-610-1400 792-610-1430 792-610-1440 Part Name Suspension tool Pump assembly H2 H6 : Pump assembly Hose Kit No. : 792-610-1100 Joint Fitting Joint Valve assembly Nipple Stem Joint Regulator assembly Gauge Gauge 24.5 MPa {250 kg/cm2} 9.81 MPa {100 kg/cm2} H7 H13 : Charging tool assembly Kit No. : 792-610-1200 Remarks
a Stop the machine empty on level ground. 1. Testing length of cylinder 1) Check that the bottom of the cylinder cover is within the range e marked by arrows for the cylinder level.
a With the truck empty, starting switch ON, parking brake OFF, and hoist control lever at the FLOAT position, check that the cylinder of the variable damper valve is in the soft mode. a If the cylinder of the variable damper valve is not in the soft mode when checking, operate as follows to switch to the soft mode. i) Use the retarder brake (Note 1) and drive the machine several times repeatedly forward and in reverse to set to the soft mode. Note 1: If the foot brake pedal is used, the automatic suspension is automatically set to the medium mode, and the resistance of the cylinder increases, so it takes time to adjust. 2. Releasing nitrogen gas 1) Front suspension cylinder i) Set hydraulic jack [1] (50ton) under the main frame. ii) Disconnect pressure sensor connector (2) of valve (1), then loosen the valve (1) 2 3 turns. a When releasing the nitrogen gas, there is danger that releasing the gas from the valve core of feed valve (3) will damage the valve core, so remove the gas at the valve (1). a When loosening the valve (1), loosen only the valve itself. Do not loosen the pressure sensor or nipple.
2) Before adjusting the oil level, check the condition of the variable damper valve. S posision : soft mode H posision: hard mode M posision: medium mode
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a When the valve (1) is loosened, and oil and gas spurt out together, tighten the valve slightly, and allow time for the gas to escape slowly. iii) Operate the hydraulic jack so that dimension a of the cylinder is the specified dimension for the oil level. Dimension a:79 3 mm (Standard) 79 3 mm (With buffer ring)
7) After completion of supplying the oil, remove the volume pump, then install feed valve (3). 3 Feed valve: 39.2 49.0 Nm {4 5 kgm}
3. Adjusting of oil level a Release the nitrogen gas before adjusting the oil level. 1) Remove feed vavle (3), and install joint H6. 2) Install fitting H5 to joint H4, then connect hose H3 and volume pump H2. 3) Loosen air bleeding valve (4), then operate volume pump H2 until no more bubbles come out with the oil from air bleed side hole b. 4) When no more bubbles come out with the oil, tighten air bleeding valve (4). 3 Air bleeding valve: 39.2 49.0 Nm {4 5 kgm}
5) Remove valve (1), then operate volume pump H2 until no more bubbles come out with the oil from the valve (1) mount. 6) When no more bubbles come out with the oil, tighten the valve (1). 3 Valve: 39.2 49.0 Nm {4 5 kgm}
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4. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). 2) Set tool H as shown in the diagram. a Before installing regulator H11, blow the connector filter with nitrogen gas at 0.981 MPa {10 kg/cm2} or more to blow out all dirt or dust. (Dirt or dust in the system causes failures.) 3) Open valve [2] of the gas cylinder [1], and check the pressure reading of gauge H12 (internal pressure of gas cylinder). a The pressure indicated must be at least 0.981 MPa {10 kg/cm2 } higher than the pressure inside the suspension cylinder (max. pressure inside suspension cylinder: 4.31 MPa {44 kg/cm2}). 4) Turn handle H11a of regulator H11 slowly clockwise, set the pressure reading of gauge H13 to 0.981 MPa {10 kg/cm 2 } above the internal pressure of the suspension cylinder, then operate valves H7 and H10 to fill the suspension cylinder with nitrogen gas. a Fill the left and right cylinders in the same way. 5) When dimension a of the left and right cylinders reaches the standard value, turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas. a Standard dimension a: 249 10 mm 6) Turn handle H10a of H10 fully back counterclockwise, loosen air bleeding plug H7a of valve H7 , release the gas inside the hose, then remove tool H. a Be careful not lose the O-ring of the feed valve.
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5. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine-empty and on level ground. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing), drive the machine forward approx. 15 m and stop suddenly, then drive in reverse to the original position and stop again suddenly. Repeat this cycle 3 4 times, and finally, allow the machine to stop slowly without depressing the brake. Then measure the installed length. a Do not use the foot brake when braking the machine. Use the retarder control lever to brake the machine, and check that the suspension is in the soft mode. 2) If the result of the check shows that the installed length is too long, release nitrogen gas to adjust the length. a Loosen the valve (1) slightly to release the nitrogen gas. When doing this, release only a small amount of gas; do not make the cylinder move. a If too much nitrogen gas is released and the cylinder moves, the installed length may be below the specified length. a Do not press the tip of the valve core. If the tip of the valve core is pressed, the valve core may be damaged. 3) After releasing nitrogen gas and adjusting the installed length, repeat Step 1) to check the installed length again. 4) Repeat the above Steps 1) 3) to adjust the cylinder to the specified length. 5) Finally, check that there is no leakage of gas from the valve core (6), valve (1), and piston rod gland. a Use soapy water to check for leakage of gas. a If there is any leakage of gas from the valve core, use tool [3] and remove the valve core.
Note:1. Checking after changing oil and gas After the oil and gas have been changed, operation of the machine causes the gas to dissolve in the new oil inside the cylinder until it is saturated, so the volume of gas is reduced and the installed length of the suspension goes below the specified limit. Therefore, 48 hours after changing the oil and gas, check the installed length of the suspension and adjust the gas if the length is not within the specified value. 2. Checking for changes in installed length caused by variation in ambient temperature. Depending on the ambient temperature when the machine is working, the gas in the suspension may expand or contract, so the installed length will also change. In territories where there are big differences in temperature throughout the year, inspect daily and adjust to keep the installed length within the specified range.
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HD465-7, HD605-7
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER

a Stop the machine empty on level ground. 1. Testing length of cylinder Check that dimension "a" of the rear suspension cylinder is within the specified value. Specified value for dimension "a" : 220 10 mm (Standard) : 204 10 mm (With buffer ring) Thickness of frange b a For the standard dimensions, see the decal stuck to the cylinder.
Standard 49 mm With buffer ring 65 mm
ii) Disconnect pressure sensor connector (2) of valve (1), then loosen the valve 2 3 turns. a When releasing the nitrogen gas, there is danger that releasing the gas from the valve core of feed valve (3) w il l d am a g e t he v a lv e c o r e , s o remove the gas at the valve (1). a When loosening the valve (1), loosen only the valve itself. Do not loosen the pressure sensor or nipple. k When loosening the valve (1), gradually loosen only valve (1) itself, and do not remove the valve until all the nitrogen gas has been released from the slit.
k If the nitrogen gas has not all been released, pressure sensor (5) are still under high pressure, so do not loosen them under any circumstances. a When the valve (1) is loosened, and oil and gas spurt out together, tighten the valve slightly, and allow time for the gas to escape slowly.
2. Releasing nitrogen gas 1) Rear suspension cylinder i) Set block [2] between the stopper and axle housing. Thickness of block: 19 mm Dimension a : 140 3 mm (Standard) : 124 3 mm (With buffer ring)
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3. Adjusting oil level a Release the nitrogen gas before adjusting the oil level. 1) Remove feed valve (3), and install joint H6. 2) Install fitting H5 to joint H4, then connect hose H3 and volume pump H2. 3) Loosen air bleeding valve (1), then operate volume pump H2 until no more bubbles come out with the oil from air bleeding valve (1). 4) When no more bubbles come out with the oil, tighten air bleeding valve (1). 5) After adding oil, remove the volume pump, then install feed valve (3).
H13 to 0.981 MPa {10kg/cm 2 } above the internal pressure of the cylinder, then operate valves H7 and H10 to fill the cylinder with nitrogen gas. a Fill the left and right cylinders in the same way. 5) When dimension "a" of the left and right cylinders reaches the standard value, turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas. a Standard dimension a : 220 10 mm (Standard) : 204 10 mm (With buffer ring) 6) Turn handle H10a of H10 fully back counterclockwise, loosen air bleeding plug H7a of valve H7 , release the gas inside the hose, then remove tool H. a Be careful not to lose the O-ring of the feed valve.
4. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). 2) Set tool H to the feed valve supply as shown in the diagram. a Before installing regulator H11, blow the filter in the connector with nitrogen gas at 0.981 MPa {10 kg/cm2} or more to blow out all dirt or dust. (Dirt or dust in the system causes failures.) 3) Open valve [2] of the gas cylinder [1], and check the pressure reading of gauge H12 (internal pressure of gas cylinder). a The pressure indicated must be at least 0.981 MPa {10kg/cm 2 } higher than the pressure inside the cylinder (max. pressure inside cylinder: 2.74 MPa {28 kg/ cm2}). 4) Turn handle H11a of regulator H11 slowly clockwise, set the pressure reading of gauge
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5. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine empty and on level ground. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing), drive the machine forward approx. 15 m and stop suddenly, then drive the machine forward approx. 15 m and stop suddenly, then drive in reverse to the original position and stop again suddenly. Repeat this cycle 3 4 times, and finally, allow the machine to stop slowly without depressing the brake. Then measure the installed length. a Do not use the foot brake when braking the machine. Use the retarder control lever to brake, the machine, then check that the suspension is in the soft mode. 2) If the result of the check shows that the installed length is too long, release nitrogen gas to adjust the length. a Loosen the valve slightly to release the nitrogen gas. When doing this, release only a small amount of gas; do not make the cylinder move. a If the nitrogen gas is so released that the cylinder may move, the installed length may be below the specified length. a Do not press the tip of the valve core. If the tip of the valve core is pressed, the valve core may be damaged. 3) After releasing nitrogen gas and adjusting the installed length, repeat Step 1) to check the installed length again. 4) Repeat the above Steps 1) 3) to adjust the cylinder to the specified length. 5) Finally, check that there is no leakage of gas from the valve core (6), valve, and piston rod gland. a Use soapy water to check for leakage of gas. a Replace valve core (6) if there is any leakage of gas from the valve core. V a l v e c o r e :
6. Testing and adjusting dust cover a To protect the rear suspension from stones and other objects thrown up by the tires when the machine is traveling, carry out inspection of the cover and repair or replace it as necessary. 1) Check visually that there are no cracks or breaks in cover (1). a If the cover is damaged, replace it with a new part. 2) Check that hooks (2) are not missing. (3 places) a If any hooks are missing, remove all mud and dirt, then install hooks. 3) Check that band (3) is not loose or missing. a If the band is loose or missing, tighten to the following torque. Band: 6.8 0.49 Ncm {69 5 kgcm}
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TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER)
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER)
1. Testing 1) Check that length "a" of hydraulic cylinder (1) is as specified under the following condition. a Condition (Mode S) (1) Machine is empty. (2) Starting switch is ON. (3) Parking brake switch is ON. (4) Work equipment control lever is at FLOAT. a Specified length "a": 352 1 mm 2) Shift the hoist lever from the FLOAT position to another position and check that hydraulic cylinder length "a" is not (is longer than) 352 1 mm. 2. Adjusting 1) Remove mounting bolt (2) of hydraulic cylinder (1) and disconnect hydraulic cylinder (1). 2) Loosen locknut (3) and adjust mounting length "a" with rod end. a Specified length "a": 352 1 mm 3) Install (Return) hydraulic cylinder (1) with mounting bolt (2). 4) Turn the starting switch to the ON position and shift the hoist lever from the FLOAT position to another position and check that length "a" of hydraulic cylinder (1) is not (is longer than) 352 1 mm. (Reference) "b" in hard mode : 383 1 mm "d" in medium mode : 414 1 mm
5) Check that the hole of bracket (5) is in the slit (part "e") in modes S and M.
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HD465-7, HD605-7
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT

a Special tool list
Symbol Part No. 799-101-5002 C1 790-261-1204 Digital hydraulic meter Part Name Analog hydraulic meter Remarks Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
Stop the machine on level ground, apply the parking brake, and put chocks under the tires. Lower the body to the frame, stop the engine, then remove the cap from the hydraulic tank and release the pressure inside the cylinder circuit.
Steering circuit
1. Measuring hydraulic pressure in steering circuit 1) Raise the hydraulic oil temperature. a Oil temperature when measuring : 45 55C 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.
2. Adjusting hydraulic pressure in steering circuit If the hydraulic pressure is not within the standard value, adjust as follows. Steering pressure (adjust with demand valve) 1) Remove cap (2), then loosen locknut (3) and turn adjustment screw (4) to adjust. a To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 2.45 MPa {25 kg/cm2}.
10860
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2) After adjusting, hold the adjustment screw with a screwdriver to prevent it from turning, then tighten the locknut and install the cap. cap: 29.4 39.2 Nm {3 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value. For details, see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT. a The pressure of crossover relief valve (5) cannot be adjusted when it is installed on the machine, so do not adjust the pressure.
Hoist circuit
1. Measuring hydraulic pressure in hoist circuit 1) Raise the hydraulic oil temperature. a Oil temperature when measuring : 45 55C 2) Remove oil pressure measurement plug (1) and install tool C1 (39.22 MPa {400 kg/cm2}). 3) Operate the hoist control lever, and move the dump body to the maximum dump position to relieve the circuit, then measure the hydraulic pressure with the engine at full throttle.
3. Measuring steering valve charge pressure 1) Remove plug (6) and install tool C1 (39.2 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit. 4. Measuring hydraulic pressure in steering cylinder 1) Remove pressure measurement plug (7) (when turning the steering to the left) or pressure measurement plug (8) (when turning the steering to the right), and install tool C1 (39.2 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit.
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2. Adjusting hydraulic pressure in hoist circuit If the hydraulic pressure is not within the standard value, adjust as follows. Hoist cylinder pressure (adjust with hoist valve) 1) Loosen locknut (2) and turn adjustment screw (3) to adjust. a To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 4.2 MPa {42.8 kg/cm2}. 2) After adjusting, hold the adjustment screw with a screwdriver to prevent it from turning, then tighten the locknut. Lock nut: 29.4 39.2 Nm {3 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value. For details, see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT.
3. Measuring hoist cylinder pressure 1) Remove plug (4) and install tool C1 (39.22 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the hoist circuit.
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TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT

a Special tool list
Symbol Part No. 799-101-5002 Part Name Analog hydraulic meter Digital hydraulic meter Nipple Adapter O-ring Remarks Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} 14 1.5 Face seal type (#02) (Female: PT 1/8)
2) Install nipple C3 and hose [2] and connect oil pressure gauge C1 [5.9 MPa {60 kg/cm2}]. 3) Start the engine and measure the oil pressure when the dump lever is in neutral.
1
790-261-1204 C
3 4
799-101-5230 799-401-3100 02896-11008
Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank.
2. Measuring dump EPC valve output pressure 1) Disconnect EPC hose (3) or (4) to be measured. (3): Dump raise side (Port PB) (4): Dump lower side (Port PA)
Measuring
1. Measuring dump EPC valve main pressure 1) Remove oil pressure pickup plug (2) (M14 x 1.5) from dump EPC valve (1) inside the hydraulic tank (inside the machine).
2) Install adapter C4 to hoist valve and connect the hose. 3) Install nipple [1] and hose [2] and connect oil pressure gauge C1 [5.9 MPa {60 kg/cm2}]. 4) Start the engine and raise or lower the dump lever and measure the circuit oil pressure.
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HD465-7, HD605-7
AIR BLEEDING FROM STEERING CYLINDER
AIR BLEEDING FROM STEERING CYLINDER

Stop the machine on a level ground, apply the parking brake, then put chocks under the tires. Before operating the steering wheel, be sure to check that there is no one around the front tires. a If the hydraulic cylinder was removed and installed or its hydraulic piping was removed, breed air from the hydraulic cylinder according to the following procedure. 1. Start engine, run engine at low idle for 5 minutes. 2. Turn the steering wheel at 30 rpm (2 seconds for one turn) to the left and right to a point approx. 50 mm from the end of the steering cylinder stroke. Repeat this action ten times. (This action is to prevent damage to the piston seal caused by compression and combustion of air in the steering cylinder.) 3. Turn the steering wheel at 30 rpm to the left and right to the end of the steering cylinder stroke. Repeat this action four times. 4. Turn the steering wheel as quickly as possible to the left and right to the end of the steering cylinder stroke. When reaching the end of the stroke at the left and right, turn the steering wheel immediately in the opposite direction, and carry out this action continuously. Repeat this action ten times in both direction.
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PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY

a Special tool list
Symbol K Part No. 792T-491-1110 Part Name Plug Remarks
When performing this procedure, be sure not to go under the dump body but stand on the ground. a The dump body lowers by itself. Keep it at safe lowering speed by adjusting the tightening 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}
a If the dump body cannot be raised because of a failure in the controller or electric system, raise it to dump the load according to the following procedure. 1. Stop the engine and remove the hydraulic tank cap to release the residual pressure from the hoist circuit. 2. Remove plug (1) and tighten tool [K] fully. a If tool [K] is tightened in fully, the spool is moved to the rising stroke end.
1) If the engine can be started, start the engine under this condition, and the dump body rises. 2) If the engine cannot be started, turn the emergency steering switch "ON" and raise the dump body with the hydraulic pressure of the emergency steering pump. a Do not operate the emergency steering pump for more than 90 seconds continuously. If the load cannot be dumped in 90 seconds, cool down the steering pump, and then operate it again. 3. Stop the engine and remove tool [K] and install plug (1). Tightening torque of plug: 44.1 53.9 Nm {4.5 5.5 kgm} 4. When lowering the dump body, remove plug (2) and tighten tool [K] slowly.
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ADJUSTING BODY POSITIONER SENSOR

a If the body positioner rod has been disconnected and connected again or the body positioner sensor has been removed and installed again, inspect and adjust the body positioner sensor as follows. a HD465-7 #7001 7056 HD605-7 #7001 7020 If the positioner link is changed, adjust it to the same value with following model. HD465-7 #7057 and up HD605-7 #7021 and up 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 voltage. a Monitoring item Code No. 34400: BODY POSITION a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
2. Adjusting link length a If the monitoring voltage is not within the normal range, adjust the length of the link as follows. 1) Loosen locknut (1). 2) Remove mounting bolt (2). 3) Turn rod end (3) to adjust the length of the link (4). a Standard installing length a: 433 mm. a Do not set installing length a less than 430 mm. HD465-7 #7001 7056 HD605-7 #7001 7020 a Standard installed length "a" of link: 440 mm a Do not reduce length "a" to below 436 mm. HD465-7 #7057 and up HD605-7 #7021 and up a Adjust the input voltage as follows. INCREASE link length to DECREASE voltage DECREASE link length to INCREASE voltage 4) Install mounting bolt (2). 5) Tighten locknut (1). 6) Repeat the checking procedure above to check that the input voltage is within the normal range.
2) Start the engine. 3) Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position and RAISE position. a When operated fully to LOWER: 0.35 0.40 V: HD465-7 #7001 7056 HD605-7 #7001 7020 0.38 0.44 V: HD465-7 #7057 and up HD605-7 #7021 and up a When operated fully to RAISE: 3.80 4.70 V
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3. Calibrating system Stop the machine on a level ground, apply the parking brake, then put chocks under the tires securely. a Hydraulic oil temperature: 80 90C 1) With the body seated perfectly, start the engine. 2) Keep the dump control lever in the FLOAT position for at least 5 seconds. a Check that the FLOAT caution lamp is turned off. 3) With the body raised to the cylinder stopper, run the engine at low idle and keep the dump control lever in the RAISE position for at least 5 seconds. 4) Run the engine at high idle and raise the body to the stroke end. Then, lower the engine speed to low idle and set the dump control lever in the FLOAT position to lower the body to the seating position. a Repeat the operations of 3) and 4) above 5 10 times. 5) Run the engine at high idle and raise the body to the stroke end. Then, keep the engine speed at high idle and set the dump control lever in the LOWER position to lower the body to the seating position. a Repeat this operation 5 10 times.
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HD465-7, HD605-7
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM

If any problem occurs in the electrical system of the engine control system or transmission control system, it may become impossible to start the engine or to move the machine off. If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system, move the machine to a safe place, then carry out troubleshooting. 1. When problem occurs in engine control system and engine cannot be started a Decide the escape method according to the following flowchart. a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
1 Did [Engiine system caution NO lamp] on machine monitor flash when engine stopped? YES 2 NO Tow machine to safe place (see note)
Is there fuel in fuel tank?
YES
5 Does engine start when folNO lowing relay is replaced? R01 (engine start relay) If there is no relay to replace or engine does not start, tow machine to safe place (see note)
Is following service code YES displayed or recorded? C441KK (ENG) 442KG (ENG) NO
Does engine start when following fuse is replaced? NO FUA (30A) BT2 --- No.3 (10A) BT2 --- No.15 (20A) BT4 --- No.10 (10A) YES Start engine and move machine (do not turn electric power ON except when absolutely necessary)
YES
6 Is following service code YES displayed or recorded? C111KT C346KT (ENG) NO 8
YES
7 If there is no controller to replace, tow machine to safe place (see note)
Does engine start when en- NO gine controller is replaced?
9 Does engine start when following speed sensor is replaced? NO Master speed sensor (SP1) Back-up speed sensor (SP2) YES Start engine and move machine (do not turn electric power ON except when absolutely necessary) If there is no speed sensor to replace or engine does not start, tow machine to safe place (see note)
Is following service code YES displayed or recorded? C115KZ (ENG) C121LC (ENG) NO 10
Does engine start when folYES lowing relay is replaced? R02 (transmission neutral relay) 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 operating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE.
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2. When problem occurs in transmission control system and machine cannot be started a Check the service code and determine the escape method from the following chart. a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
Failure code 1380MW 1500L0 15G0MW 15H0MW 15J0MW 15K0MW 15L0MW 15M0MW 15N0MW 15SBL1 15SBMA 15SCL1 15SCMA 15SDL1 15SDMA 15SEL1 15SEMA 15SFL1 15SFMA 15SGL1 15SGMA 15SHL1 15SHMA 15SJL1 15SJMA D1B0KZ DAQ0KK DAQ2KK DAQ9KM DAQ9KQ DAQAKQ DAQSMA DDTGKA DDTHKA DDTJKA DDTKKA DDTLKA DDTMKA DDTNKA DDTPKA Condition when failure occurred Occurrence condition 1 Occurrence condition 2 Occurrence condition 2 Occurrence condition 3 Occurrence condition 3 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 1 Occurrence condition 1 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 4 Occurrence condition 4 Occurrence condition 4 Occurrence condition 4 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Escape method Lever position for speed range to move off after escape operation Remarks Occurrence condition 1: Speed range remains fixed; when the machine is moved off again, speed range does not shift. a When lever is returned to N, transmission shifts to neutral. Occurrence condition 2: Transmission suddenly shifts to neutral when the machine is traveling; after machine is stopped, transmission stays in neutral even when lever is operated, and machine does not move off. Occurrence condition 3: Transmission suddenly shifts to neutral. Occurrence condition 4: After engine is started, transmission stays in neutral even when lever is operated, and machine does not move off. Occurrence condition 5: Response of lever becomes abnormal; lever does not work as operated When lever is operated, transmission shifts to neutral. Occurrence condition 6: Speed range remains fixed; when the machine is moved off again, speed range does not shift. a When lever is returned to N, transmission shifts to neutral, but after that, transmission does not shift to any speed range. Note 1: Even when the machine condition is restored after a failure, the neutral condition is maintained until the lever is returned to the N position. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller.
Escape procedure 1 D L : F2, R : R Escape procedure 2 Escape procedure 3 D L : F2 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 3 D L : F2, R : R Escape procedure 3 D L : F1, R : R Escape procedure 3 D L : F2, R : R Escape procedure 3 D L : F2, R : R Escape procedure 1 Escape procedure 1 D L : F2 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F1 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2 Escape procedure 1 D L : F1, R : R Escape procedure 1 D L : F4 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F6 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Normal travel possible if display Escape procedure 4 returns to normal (Note 1) Normal travel possible if display Escape procedure 5 returns to normal (Note 1) Normal travel possible if display Escape procedure 4 returns to normal (Note 1) Normal travel possible if display Escape procedure 9 returns to normal (Note 1) Normal travel possible if display Escape procedure 7 returns to normal (Note 1) Normal travel possible if display Escape procedure 7 returns to normal (Note 1) Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F1 Escape procedure 1 D L : F2 Escape procedure 1 D L : F4 Escape procedure 1 Escape procedure 1 D L : F6 R:R R:R
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Failure code DF10KA DF10KB DLE2KA DLE2LC DLF1KA DLF1LC DLF2KA DLF2LC DLT3KA DLT3LC DXH1KB DXH2KA DXH2KB DXH3KA DXH3KB DXH4KA DXH4KB DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXHHKA DXHHKB (Note 2)
Condition when failure occurred Occurrence condition 5 Occurrence condition 2 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 6 Occurrence condition 6 Occurrence condition 1 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 2
Escape method
Lever position for speed range to move off after escape operation
Remarks Note 1: Even when the machine condition is restored after a failure, the neutral condition is maintained until the lever is returned to the N position. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller.
Normal travel possible if display Escape procedure 8 returns to normal (Note 1) Normal travel possible if display Escape procedure 8 returns to normal (Note 1) Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F1, R : R Escape procedure 1 D L : F2, R : R Escape procedure 3 D L : F2, R : R Escape procedure 3 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F1, R : R Escape procedure 1 D L : F1, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F4 Escape procedure 1 D L : F1 Escape procedure 1 D L : F2, R : R Escape procedure 1 D L : F2, R : R Normal travel possible if display Escape procedure 5 returns to normal (Note 1)
Escape procedure 1: 1) Stop traveling and return the gearshift lever to the N position. 2) Operate the gearshift lever again and move the machine OFF. a When operating the gearshift lever, release the accelerator pedal. a N o D L or N o R Escape procedure 2: Tow the machine. a If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE.
Escape procedure 3: 1) Stop traveling and return the gearshift lever to the N position. 2) Connect and disconnect emergency escape connectors A1 (female) and A2 (male), and switch to the emergency escape mode. a Connectors A1 and A2 are installed to near the fuse box. a Connect and disconnect the connectors with the starting switch at ON or with the engine started. 3) Operate the gearshift lever again and move the machine OFF. a When operating the gearshift lever, release the accelerator pedal. a N o D L or N o R a The emergency escape mode is maintained until the starting switch is turned OFF.
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Escape procedure 4: Replace the transmission cut relay. Transmission cut relay: R15 Escape procedure 5: Check the circuit breaker and fuse, and if they are normal, replace the transmission controller. Circuit breaker: No. 23 (80A) Fuse: BT3-No. 14 (10A) Escape procedure 6: Check the fuse unit and fuse, and if they are normal, replace the transmission controller. Fuse unit: Inside battery housing (30A) Fuse: BT2-No. 22 (10A) Escape procedure 7: Check the model selection setting, and if it is normal, replace the transmission controoler. a For details of checking the model selection setting, see ADJUSTING TRANSMISSION CONTROLLER. Escape procedure 8: Check the fuse, and if it is normal, replace the gearshift lever. Fuse: BT3-No. 10 (10A) Escape procedure 9: Check the transmission controller harness, and if it is normal, replace the transmission controller.
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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 connectors (OP1 OP7)
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In the following cases, check the settings of the rotary switches, dipswitches, and option setting connectors at the rear face of the machine monitor (EMMS), and change the settings as necessary. When the machine monitor has been removed and installed again. When machine monitor (EMMS) have been replaced with new parts (service meter, odometer, reverse travel odometer setting) a When carrying out of these settinigs, it is necessary to use the special operation of the character display and mode switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). When service code [DAFOKM] is displayed a There is probably mistaken connection of the option setting connector, so see TROUBLESHOOTING 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 SW1 SW2 0F SW3 1 ON OFF 2 SW5 3 ON OFF 4 ON OFF 1 ON OFF 2 SW6 ON OFF 3 ON OFF 4 ON Spare Spare Spare Setting of caution when body is raised: Installed Spare Connected Maintenance function: Installed Setting of caution when body is raised: Not installed Front brake cut: Installed Maintenance function: Not installed Spare Front brake cut: Not installed Open (Not connected) Connected Open (Not connected) Connected Open (Not connected) ON OFF Exhaust brake: Installed Spare 0F OFF Position 0F Purpose of switch Correction of travel speed (Correction of tire size) Setting of max. speed Setting of max. speed when body is raised Setting of specification Unit of speed meter: km/h Unit of speed meter: MPH Exhaust brake: Not installed Connector Unnecessary Remarks Standard tire is set to position 7.
Unnecessary Unnecessary Unnecessary Unnecessary Open (Not connected) Connected Only in area where MPH is used as unit
The condition of each switch and connector can be checked with the special function of the machine monitor (EMMS) (monitoring function). Connector OP7 is used for the special function of the machine monitor. a For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).
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a All setting operations are carried out with the starting switch OFF and the monitor panel removed. a Always set each switch and connector as instructed. a Be careful not to touch anything inside the grommet except for the switch. a When turning the rotary switch, use a precision cross-head screwdriver and turn slowly. a The protruding triangular part of the rotary switch is the setting arrow. a When changing the dipswitch, use a precision flat-headed screwdriver and turn slowly. a When setting, always avoid foreign matters or dust. a After setting, be sure to install grommet.
1. Setting rotary switch SW1 Rotary switch SW1 is used to set the travel speed compensation. The machine monitor uses the size of the standard tire to calculate the travel speed. If the tire size is changed, adjust the position of the switch to compensate for the speed display. a Tire size and setting position.
Tire size 24.0 35PR SW1 7 Connector Not needed Remarks HD465-7 standard tire
a The connector in the table indicates the number of the connector to be connected or released when changing the setting. (In the case of SW1, there is no need to connect or release the connector.) a Travel speed compensation using SW1
Position 0 1 2 3 4 5 6 7 Speed compensation +7% +6% +5% +4% +3% +2% +1% 0% Position 8 9 A B C D E F Speed compensation 0% 1% 2% 3% 4% 5% 6% 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 SW2 0 1 2 3 4 5 6 7 8 9 A B C D E F Setting of max. speed F7 (Default) F5 F4 F6 F5 F4 F6 F5 F4 F6 F5 F4 Setting of max. speed when body is raised F2 (Default) F2 F2 F2 F3 F3 F3 F3 N N N N
Connector OP3 Setting is made: Connected Setting is not made: Open (Not connected)
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3. Setting rotary switch SW3 Rotary switch SW3 is used for setting when the functions of (ASR), ASRC, AUTO SUS, (ABS), etc. are changed.
Position of SW3 0 1 2 3 4 5 6 7 8 9 A B C D E F Function Not set (ASR) ARSC AUTO SUS (ABS) (ASR, ARSC) (ASR, AUTO SUS) (ARS, ABS) (ARSC, AUTO SUS) (ARSC, ABS) (AUTO SUS, ABS) (ASR, ARSC, AUTO SUS) (ASR, ARSC, ABS) (ASR, AUTO SUS, ABS) (ASRC, AUTO SUS, ABS) (ASR, ARSC, AUTO SUS, ABS)
7. Setting dipswitch SW5-4 Use dipswitch SW5-4 to set the front brake cut. When the front brake cut has been installed or removed, set as follows.
Front brake cut Not installed Installed SW5-4 OFF ON Connector OP4 Released (Not installed) Connected Remarks
8. Setting dipswitch SW6-1 Dip switch SW6-1 is used for setting when the maintenance function is changed.
Maintenance function Not installed Installed SW6-1 OFF ON Connector OP5 Open Installed Remarks
9. Setting dipswitch SW6-2 Dip switch SW6-2 is used for setting when the caution for raising the body is changed.
Setting caution for raising body Not installed Installed SW6-2 OFF ON Connector OP6 Open Connected Remarks
Connector OP2 Setting is made: Connected Setting is not made: Open (Not connected)
4. Setting dipswitch SW5-1 Dipswitch SW5-1 is set as follows. The setting must not be changed. a Turn ON this switch only in an area where MPH is used as the unit.
SW5-1 OFF ON Connector Unnecessary Unnecessary Remarks Unit of speedometer: km/h Unit of speedometer: MPH
10. Setting dipswitch SW6-3 Dipswitch SW6-3 is set as follows. The setting must not be changed. Set position of dipswitch SW6-3: OFF Connector operation: Not needed 11. Setting dipswitch SW6-4 Dipswitch SW6-4 is set as follows. The setting must not be changed. Set position of dipswitch SW6-4: OFF Connector operation: Not needed
5. Setting dipswitch SW5-2 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 Installed ON SW5-2 OFF ON Connector OP1 Open Connected Remarks
6. Setting dipswitch SW5-3 Dipswitch SW5-3 is set as follows. The setting must not be changed. Set position of dipswitch SW5-3: OFF Connector operation: Not needed
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ADJUSTING TRANSMISSION CONTROLLER
ADJUSTING TRANSMISSION CONTROLLER

1. Setting rotary switch a If the transmission controller has been replaced, set the rotary switches for the network data and model selection as follows. a Use a precision cross-head screwdriver and turn the rotary switch slowly. a The e mark on the rotary switch is the guideline for setting. 1) Remove 2 grommets at the top of the controller. 2) Align the SW1 rotary switch and SW2 rotary switch with the set position. a Set rotary switches 1 and 2 (SW1 and SW2) to only the following positions (1) Contents of setting and set position of rotary switch 1 (SW1) Table 1
Switch SW1 Contents of setting Model information Position 4
2. Setting machine body wiring harness a If the transmission controller is replaced, set the connector for selecting the model as shown below.
HD465, 605-7 MS11 MS12 MS21 MS22 MS31 MS32 Connected Open Connected
(2) Contents of setting and set position of rotary switch 2 (SW2) (See table 2)
3. Adjusting transmission a After carrying out any of the following operations, adjust the transmission in order to adjust the fitting between the transmission and the transmission controller. When the transmission has been overhauled or replaced When the transmission control valve has been repaired or replaced When the transmission controller has been replaced When the power train speed sensor has been repaired or replaced When the transmission oil temperature sensor has been repaired or replaced When the transmission oil filter has become clogged and has been cleaned a When adjusting the transmission, use the service function of the machine monitor. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
Table 2
Switch VHMS controller Not installed Not installed SW2 Installed Installed Installed PLM function in VHMS controller Card-type payload meter (PLM- ) Not installed Installed Not installed Installed Not installed Function of payload meter (PLM) function Not installed Installed Not installed Installed Installed Position F F B B 9

Not installed Not installed Installed
a The transmission controller switch (SW2) is used to notify the monitor panel "whether the VHMS is installed", "whether the PLM function in the VHMS is turned on", and "whether PLM- is installed".
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HD465-7, HD605-7

In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to Table 1. 1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time 2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller (PLM ) is changed Table 1
Setting with VHMS initial setting manual (tool) (*2) Date Time Time difference (GMT) Summer time Set properly
VHMS controller
PLM function in VHMS controller
Card-type payload meter (PLM- )
Payload meter (PLM) function
Set position of rotary switch 2 (SW2) of transmission controller (*1)
Model
Type
Variation code
Not installed Not installed Installed Installed Installed
Not installed Not installed Installed Installed
F F B F 9
HD465 or HD605
ST
Not installed Not installed Not installed Not installed Installed Installed Installed Installed Installed
P2 PV
(*1) For the set position of rotary switch 2 (SW2) of the transmission controller, see the section of adjustment of the transmission controller. (*2) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool) When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. a Wrong setting of rotary switch 2 (SW2) of transmission controller 2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on the machine monitor. a Wrong setting of rotary switch 2 (SW2) of transmission controller 3. While the payload meter in the VHMS is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 4. The storage place of the data file made by the download software is not found. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. a Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. a Wrong setting of the date and time with the VHMS initial setting tool.
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SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT

In the following cases, set the rotary switches and DIP switches on the side of the card-type payload meter and set the threshold value of turning on the external indicator lamp and option code with the switches on the front. When card-type payload meter is installed for the first time When card-type payload meter is replaced
1. Setting of switches 1) Remove cover (1) from the left side of the card-type payload meter.
2) Set the following switches. (See view Z in the above figure.) Set the model selector switch (No. 4).
Position of rotary switch 7 A Model HD465-7 HD605-7
Set weight unit setting switch (No. 7).

Position of switch Upper Lower Model Metric ton American ton (Short ton)
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Set buzzer volume switch (No. B) and switch forcible prohibition switch (No. 8), if necessary. When changing these switches from the initial positions, be sure to check with the Operation and Maintenance Manual. Do not change the load weight correction trimmer (No. 1) from the initial position. Do not change the speed correction switch (No. 2), distance correction switch (No. 3), memory card using switch (No. 5), and clinometer using switch (No. 6) from the initial positions.
Switch Speed correction switch (No. 2) Distance correction switch (No. 3) Memory card using switch (No. 5) Clinometer using switch (No. 6) Switch forcible prohibition switch (No. 8) Initial setting Switch position: 7 Switch position: 7 Switch position: Lower (Use) Switch position: Lower (Use) Switch position: Upper (Permission)
a You can carry out the operations of calibration, clearing all data, dumping card, and setting date by turning switches No. 5 and No. 8 ON or OFF. (See the Operation and Maintenance Manual.) 2. Setting of option code a Required for communication with personal computer The option code is set to zero (0) initially. For HD465-7 and HD605-7, check that the option code is zero by the following method. When the power is turned ON, "OP: 0" is indicated before the normal operation display starts. (See Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indication.)
Execution of automatic transmission function NO YES NO YES NO YES NO YES NO NO NO NO Optional setting Setting of TALKS NO NO NO NO YES YES YES YES YES YES NO NO Setting of PMC NO NO NO NO NO NO NO NO YES YES YES YES Type of transmission of data when dumping is finished (when PMC is set) Z1 Z2 Z1 Z2
Option code
Transmission baud rate (bit/sec)
0 1 2 3 4 5 6 7 8 9 10 11
9600 9600 1200 1200 9600 9600 1200 1200 9600 9600 9600 9600
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Method of changing option code 1) Set the gearshift lever in "N" and the dump lever in FLOAT. Operation switches to be used MODE (2) LIGHT/INC (3) TOTAL/SFT (4) CAL/CLR (5) Screen (6) a While watching the screen, operate switches (2) (5) to set values.
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2) Display the option code screen according to the following procedure.

Press MODE switch (2). Press MODE switch (2) for 2 seconds. Cd: dp (Cd lights up and dp blinks) 0. XXX (0. XX lights up and X at ones place blinks)
Display
Display
XXX = Currently set operator ID
O O
Press MODE switch (2). Press MODE switch (2). A. CLE (A lights up and CLE blinks) SP: XX (SP: X lights up and X at ones place blinks)
Display
Display
XX = Current set limit speed (km/h)
O O
Press MODE switch (2). Press MODE switch (2). OP: XX (OP: X lights up and X at ones place blinks)
Display
Display
F. CHE (F. CHE blinks)
XX = Current set option code
Press MODE switch (2). d. XXX (d. XX lights up and X at ones place blinks)
Display
XXX = Currently set machine ID
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3) Changing set value of option code a You can change the digit at the blinking place. Changing ones digit
Press LIGHT/INC switch (3). OP: XX (OP: X lights up and X at tens place blinks)
Display
XX = Tens digit of currently set option code is increased by 1.
Changing place to be changed a Press TOTAL/SFT switch (4). o The blinking point moves to the ones place.
Press LIGHT/INC switch (3). OP: XX (OP: X lights up and X at ones place blinks)
Display
XX = Ones digit of currently set option code is increased by 1.
Changing tens digit a Press TOTAL/SFT switch (4). o The blinking point moves to the tens place.
4) Finishing setting a Press MODE switch (2).
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HD465-7, HD605-7
3. Setting threshold value of external indicator lamp a When installing the card-type payload meter to a machine having the 3-bulb external indicator lamp (HD465-7, HD605-7), be sure to set the threshold value of the external indicator lamp. 1) Set the gearshift lever in "N" and the dump lever in FLOAT. 2) Set the threshold value of the external indicator lamp according to the following procedure. a For the setting switches, see "2. Setting of option code", Method of changing option code.
Press MODE switch (2) and LIGHT/INC switch (3) simultaneously for 3 seconds.
Press CAL/CLR switch (5). PL: XX (PL: lights up and XX blinks)
Display
O
Press CAL/CLR switch (5).
Display
O. SEL (O. SEL lights up)
O
Display CHEC (CHEC blinks) Press CAL/CLR switch (5).
Display
P. SEL (P. SEL lights up)
O
Press TOTAL/SFT switch (4) and LIGHT/INC switch (3) simultaneously for 2 seconds.
O
Display S. SEL (S. SEL lights up) Press CAL/CLR switch (5).
Display
H. SEL (H. SEL lights up)
Press CAL/CLR switch (5).
O
Display UP: XX (UP: lights up and XX blinks) Press CAL/CLR switch (5).
Display
E. SEL (E. SEL lights up)
O HD465-7, HD605-7
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Press TOTAL/SFT switch (4). A. XXX (A. lights up and XXX blinks)
Press LIGHT/INC switch (3). c. XXX (c. lights up and XXX blinks)
Display
Display
XXX = Currently set display level of external lamp 1
XXX = Set to 050.
a If LIGHT/INC switch (3) is held, XXX increases to 255 and then returns to 0. O
Press CAL/CLR switch (5). b. XXX (b. lights up and XXX blinks)
Display
Press CAL/CLR switch (5). d. XXX (d. lights up and XXX blinks)
Display
Press CAL/CLR switch (5). c. XXX (c. lights up and XXX blinks)
Display
Press LIGHT/INC switch (3). d. XXX (d. lights up and XXX blinks)
Display
XXX = Set to 090.
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HD465-7, HD605-7
Press CAL/CLR switch (5). E. XXX (E. lights up and XXX blinks)
Display
4. Check of setting For 30 seconds after the card-type payload meter is turned ON, the model selection code, setting of memory card using switch, setting of clinometer using switch, setting of weight unit setting switch, setting of switch forcible prohibition switch, and setting of option code are displayed. Check that they are correct. a For contents of indication made when the power is turned ON, see Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indication.
Press LIGHT/INC switch (3). E. XXX (E. lights up and XXX blinks)
Display
XXX = Set to 105. (HD465-7) XXX = Set to 100. (HD605-7)
Press MODE switch (2).
Display
CHEC (CHEC blinks)
Press MODE switch (2).
End of setting
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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 displayed on the character display in the middle of the machine monitor. The display items are divided by the internal setting of the machine monitor (EMMS), into automatic display items and items displayed when the machine monitor switches are operated. 1) Normal functions: Operator mode Functions for which the content is normally displayed or which can be displayed and operated by the operator operating the switches. 2) Special functions: Service mode Functions which the serviceman can display and operate with the special switches to carry out inspection, maintenance, and troubleshooting.
Operator mode 1 2 3 4 5 6 7 8 Service meter, odometer display function (default) (*1) Reverse travel distance display function Filter replacement, oil change interval display function Telephone number input function Language selection function PLM setup function Action code display function Failure code display function 16
i o
9 10 11 12 13 14 15
Service mode Electric system fault history display function Mechanical system fault history display function Machine data monitoring function Adjustment function Filter replacement, oil change interval display function Snapshot function PLM setting function Initialize function (factory use only)
*1: PLM (payload meter) display function when receiving VHMS data
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FLOW MODES AND FUNCTION
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Operator mode a [>], [<], [ ], [t], give an endless display according to the operation of the switch. a When a failure occurs, the screen changes automatically to ACTION CODE DISPLAY FUNCTION, regardless of the display screen. a Regardless of the display screen, if no switch is operated for more than 30 seconds, the screen automatically changes as follows. Goes to SERVICE METER, ODOMETER DISPLAY FUNCTION: If there is no failure Goes to ACTION CODE DISPLAY FUNCTION: If there is a failure a From FAILURE CODE DISPLAY FUNCTION the screen changes to SERVICE METER, ODOMETER DISPLAY FUNCTION with the switch operation, and if no switch is operated for more than 10 seconds, the screen automatically changes to ACTION CODE DISPLAY FUNCTION. Service mode a For selection of each function, [>], [<], [ ], [t],give an endless display according to the operation of the switch. a Once the ID is input and confirmed, it remains effective until the starting switch is turned OFF.
Character display The character display consists of a top line and bottom line with 16 characters each. A combination of the following characters (alphabet and numerals) and symbols is displayed according to the content. 1) Numerals: 1, 2, 3 . . . 2) Small letters: a, b, c . . . 3) Capital letters: A, B, C . . . 4) Katakana: Japanese display only 5) Symbols: @, , $ . . . 6) Special characters Control switches Control of the machine monitor display is all carried out with machine monitor mode selector switches (1) and (2). The following functions are provided for the buttons of each switch. 1) : Select, Run 2) t: Cancel, Release, Select (YES/NO only) 3) >: Right, Next, Continue 4) <: Left, Previous, Return
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Operation and displays for operator mode 1. Service meter, odometer display function When the starting switch is turned ON, the top line shows the service meter and the bottom line shows the odometer (Fig. 1) a For details, see STRUCTURE AND FUNCTION, Machine monitor system.
2. Reverse travel distance display function Use the switch to display the total distance traveled in reverse of the machine monitor (Fig. 2) a For details, see STRUCTURE AND FUNCTION, Machine monitor system.
3. Filter, oil replacement interval display function 1) Filter, oil replacement time display (automatic display) When the replacement interval for the filters or oil approaches, this information is automatically displayed on the machine monitor to recommend the operator to carry out maintenance (Fig. 3: example).
2) Resetting replacement time (selection menu) When the maintenance operation for the filters and oil replacement has been completed, the switches on the machine monitor can be used to reset the interval (Fig. 4) a For details, see STRUCTURE AND FUNCTION, Machine monitor system. a The replacement time can be set using Service mode.
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4. Telephone number input function The telephone number set inside the machine monitor can be input, corrected, or canceled by operating the switches (Fig. 5). a When action code [E03] is displayed, the telephone number is displayed at the same time as [CALL]. a For details, see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR".
5. Language selection function The language used for the machine monitor display can be selected by operating the switches (Fig. 6) a The functions of Service mode is not included in the functions for display selection, so it is always displayed in English. a For details, see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR".
6. PLM setting function a This function is applied to the "PLM in VHMS" (Only when the option is set). Various functions of the "PLM in VHMS" are displayed and set (FIG. 10). a For details, see the operation manual for the "PLM in VHMS".
7. Action code display function If any abnormality occurs on the machine, the degree of the abnormality is automatically displayed as a user code on the machine monitor to recommend appropriate action to the operator (Fig. 7). a The diagram on the right shows an example of action code [E03] and [CALL+ Telephone number] being displayed in turn. a When action codes [E01] and [E02] are displayed, [CALL+ Telephone number] is not displayed. a Correspondence between action code and recommendation to operator
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Action code E01
CALL+ Telephone number Not displayed
Action recommended to operator Carry out testing and adjusting after completion of operations or when changing shifts between operators When overrun related display is shown: Reduce engine speed and machine speed while continuing operations. 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 serviceman.
E02
Not displayed
E03
Displayed
8. Failure code display function While the action code is being displayed on the machine monitor, press the [>] button once to display the failure codes for the existing failures (Fig. 8: example). [>] Button: Displays failure code a The failure codes detected in the past are divided into failures of the electrical system and the mechanical system and are recorded as fault history. (For details, see Service mode.) a If more than one failure is occurring, press the [>] button once more to display the other failure codes. a After pressing the [>] button to display all the existing failures, press the [>] button once more to return to the service meter/odometer display screen. If the [>] button is pressed once more, the failure codes will be displayed again from the beginning. If the switch is not operated for 10 seconds, the display will switch automatically to the action code screen. a With the service code display function, the following data are displayed (Fig. 9). A: Failure code (4 digits for location code + 2 digits for problem code) B: Controller code (MON: Machine monitor) (ENG: Engine controller) (TM: Transmission controller) (BK: Retarder controller) C: System with problem a For details of the displayed failure codes, see FAILURE CODE TABLE. a With the failure code display function and fault history display function (Service mode), the data that are displayed are partially different. a If no switch is operated on the failure code display screen for more than 30 seconds, the display automatically returns to the action code display screen.
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FAILURE CODES LIST

Failure code 1380MW 1500LO 15B0NX 15E0KM 15E7KM 15G0MW 15H0MW 15J0MW 15K0MW 15L0MW 15M0MW 15N0MW 15SBL1 15SBMA 15SCL1 15SCMA 15SDL1 15SDMA 15SEL1 15SEMA 15SFL1 15SFMA 15SGL1 15SGMA 15SHL1 15SHMA 15SJL1 15SJMA 2F00KM 2G42ZG 2G43ZG 989AOO 989AKZ 989OO Lockup clutch Detection of double engagement Clogging of steering oil filter R o F gear shifting abuse 1 R o F gear shifting abuse 2 R clutch Hi clutch Lo clutch 1st clutch 2nd clutch 3rd clutch 4th clutch R clutch ECMV R clutch ECMV Hi clutch ECMV Hi clutch ECMV Lo clutch ECMV Lo clutch ECMV 1st clutch ECMV 1st clutch ECMV 2nd clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 3rd clutch ECMV 4th clutch ECMV 4th clutch ECMV Lockup clutch ECMV Lockup clutch ECMV Parking brake Accumulator (Front) Accumulator (Rear) Engine overrun prevention command signal Engine overrun prevention command signal Rear part tipping signal Failed section Failure phenomenon (Phenomenon/Contents of failure) Slip (MW) * See separate list (L0) Clogging (NX) Mistake in operation or setting (KM) Mistake in operation or setting (KM) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) Mistake in operation or setting (KM) Lowering of oil pressure (ZG) Lowering of oil pressure (ZG) Operation (OO) Disconnection or short circuit (KZ) Operation (OO) Controller TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM BK BK TM TM BK Action code E03 E03 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E02 E01
20-168
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HD465-7, HD605-7
Failure code AA10NX AB00MA B@BCZK B@C7NS B@CENS C111KT C112LK C113KZ C115KZ C116KX C117KX C118KX C119KX C121LC C122KX C123KX C131KX C132KX C135KX C141KX C143ZG C144KX C145KX C148KX C151NS C153KX C154KX C221KX C222KX C234N1 C254KZ C259FS C261NS C263KX
Failed section Air cleaner element Alternator Radiator coolant Rear brake oil Torque converter Failure in controller memory Timing actuator defective Abnormal current in timing actuator Error in engine speed sensor 2 system Abnormality in timing rail pressure sensor Abnormality in timing rail pressure sensor Abnormality in fuel pump pressure sensor Abnormality in fuel pump pressure sensor Error in engine speed sensor 1 system Abnormality in boost pressure sensor Abnormality in boost pressure sensor Abnormality in throttle sensor Abnormality in throttle sensor Abnormality in oil pressure sensor Abnormality in oil pressure sensor Lowering of oil pressure (Engine protection) Abnormality in coolant temperature sensor Abnormality in coolant temperature sensor Abnormality in FM throttle Rise of coolant temperature (Engine protection) Abnormality in intake air temperature sensor Abnormality in intake air temperature sensor Abnormality in atmospheric pressure sensor Abnormality in atmospheric pressure sensor Engine over-speed Abnormality in FSOV circuit Abnormality in FSOV circuit Rise of fuel temperature (Engine protection) Abnormality in fuel temperature sensor
Failure phenomenon (Phenomenon/Contents of failure) Clogging (NX) Malfunction (MA) Lowering of level (ZK) Overheating (NS) Overheating (NS) Internal defect of controller (KT) * See separate list (LK) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Clogging (NX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) * See separate list (LC) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Disconnection or short circuit (KZ) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Overheating (NS) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Overrun (N1) Disconnection or short circuit (KZ) Fixing (FS) Overheating (NS) Out of input signal range (KX)
Controller TM TM TM MON MON ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
Action code E01 E03 E01 E02 E02 E03 E03 E03 E03 E03 E03 E01 E01 E03 E03 E03 E03 E03 E01 E01 E03 E01 E01 E03 E02 E01 E01 E03 E03 E02 E03 E03 E02 E01
HD465-7, HD605-7
20-169
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Failure code C265KX C316KZ C318LK C346KT C423L6 C431L4 C432L5 C441KK C442KG C451KX C452KX C455KZ C467LK C468LK C514LK C554L6 D1B0KZ D1C0KZ D5ZMKZ D5ZNKZ DAF0KM DAF9KM DAFSKQ DAQ0KK DAQ1KK DAQ2KK DAQ3KK DAQ9KM DAQ9KQ DAQAKQ DAQSKR DAQSMA DASRKR DB10KK
Failed section Abnormality in fuel temperature sensor
Failure phenomenon (Phenomenon/Contents of failure) Out of input signal range (KX)
Controller ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG TM BK TM BK MON MON MON TM TM TM TM TM TM TM MON TM MON BK
Abnormal current in fuel injection pump actuator Disconnection or short circuit (KZ) Pump actuator defective ECM power-down error Timing rail pressure in-range error Abnormality in idle validation switch Idle validation process error Abnormality in battery voltage Abnormality in battery voltage Abnormality in fuel rail pressure sensor Abnormality in fuel rail pressure sensor Abnormality in fuel rail actuator circuit Timing actuator control error Fuel rail actuator control error Fuel rail actuator defective Fuel rail pressure sensor in-range error Transmission cut-out relay Brake cut-out relay
Disconnection/Grounding fault/Short circuit in engine output mode command line Failure in front brake cut-out output system (Disconnection, grounding fault, short circuit) (OPT)
* See separate list (LK) Internal defect of controller (KT) * See separate list (L6) * See separate list (L4) * See separate list (L5)
Lowering of source/input voltage (KK)
High source voltage (KG) Out of input signal range (KX) Out of input signal range (KX) Disconnection or short circuit (KZ) * See separate list (LK) * See separate list (LK) * See separate list (LK) * See separate list (L6) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Mistake in operation or setting (KM) Mistake in operation or setting (KM)
Disagreement of model selection signals (KQ) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK)
Monitor panel Monitor panel Monitor panel Transmission controller Transmission controller main power source line Transmission controller load power source line
Transmission controller battery direct power source line
Transmission controller wiring harness Transmission controller wiring harness Transmission controller rotary switch Transmission controller S-NET line Transmission controller COMMUNICATION ERROR ENG Retarder controller
Mistake in operation or setting (KM)

Disagreement of model selection signals (KQ) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR)
Malfunction (MA)
Communication defective/Abnormality in objective component (KR)
Lowering of source/input voltage (KK)
20-170
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HD465-7, HD605-7
Failure code DB11KK DB12KK DB13KK DB19KM DB1SKR DB1SKQ DBBSKR DDD7KX DDD8KA DDD8KB DDDAKA DDDAKB DDTGKA DDTHKA DDTJKA DDTKKA DDTLKA DDTMKA DDTNKA DDTPKA DF10KA DF10KB DGF1KX dGR2L8 DGR2L8 DGT1KX dHP4KX DhP4KX DHP4KX dHP5KX DhP5KX DHP5KX DHP6KX DHP7KX
Failed section Retarder controller main power source line Retarder controller load power source line
Retarder controller battery direct power source line
Failure phenomenon (Phenomenon/Contents of failure)

Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK)
Controller BK BK BK BK MON BK MON BK BK BK BK BK TM TM TM TM TM TM TM TM TM TM TM BK BK TM BK PLM BK BK PLM BK PLM PLM
Retarder controller wiring harness Retarder controller S-NET line Wrong information on model selection Communications error VHMS
Failure in travel speed setting switch system (OP)
Mistake in operation or setting (KM)

Communication defective/Abnormality in objective component (KR) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR)
Out of input signal range (KX) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Short circuit (KB) Out of input signal range (KX) * See separate list (L8) * See separate list (L8) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX)
Disconnection ARSC system switch (OP) Short circuit ARSC system switch (OP) Disconnection ASR system switch (OP) Short circuit ASR system switch (OP) Fill switch for lockup clutch Fill switch for Hi clutch Fill switch for Lo clutch Fill switch for 1st clutch Fill switch for 2nd clutch Fill switch for 3rd clutch Fill switch for R clutch Failure in flow sensor valve for 4th clutch Gear shift lever Gear shift lever Transmission valve oil temperature sensor
Failure in retarder oil temperature sensor system
Brake oil temperature sensor (Rear) Torque converter oil temperature sensor
Failure in suspension pressure sensor (FR) system (OPT)
Suspension pressure sensor (FR)

Failure in suspension pressure sensor (FR) system (OPT) Failure in suspension pressure sensor (FL) system (OPT)
Suspension pressure sensor (FL)

Failure in suspension pressure sensor (FL) system (OPT)
Suspension pressure sensor (RR) Suspension pressure sensor (RL)
HD465-7, HD605-7
20-171
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Failure code DHT5KX DHT5L6 DHU2KX DHU3KX DJF1KA DK11KX dK11KX Dk11KX DK30KX DK51L5 DK52KX DK53L8 DK54KX DKD0L6 DKH1KX DLE2KA DLE2LC DLF1KA DLF1LC DLF2KA DLF2LC DLF8KA DLF8LC DLF9KA DLF9LC DLT3KA dLT3KA dLt3KA DLT3LC DLT3LC dLT3LC DV00KB DW35KZ DW36KZ
Failed section Torque converter oil pressure sensor Torque converter oil pressure sensor Accumulator oil pressure sensor (Front) Accumulator oil pressure sensor (Rear) Fuel level sensor Throttle angle sensor Failure in acceleration sensor system (OPT) Failure in acceleration sensor system (OPT) Failure of steering angle potentiometer (OP) Retarder lever potentiometer Dump lever potentiometer 1 Dump lever potentiometer 2 Body positioner sensor Failure in steering speed sensor (OPT) Abnormality in angle sensor Engine speed sensor Engine speed sensor Transmission input shaft speed sensor Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission intermediate shaft speed sensor
Disconnection in wheel speed sensor (RR) (OP)
Failure phenomenon (Phenomenon/Contents of failure) Out of input signal range (KX) * See separate list (L6) Out of input signal range (KX) Out of input signal range (KX) Disconnection (KA) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) * See separate list (L5) Out of input signal range (KX) * See separate list (L8) Out of input signal range (KX) * See separate list (L6) Out of input signal range (KX) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) Disconnection (KA) Disconnection (KA) * See separate list (LC) * See separate list (LC) Disconnection (LC) Short circuit (KB) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ)
Controller TM TM BK BK TM TM BK BK BK BK BK BK BK BK PLM TM TM TM TM TM TM BK BK BK BK TM BK BK TM BK BK MON BK BK
Failure in wheel speed sensor (RR) system (OP)

Disconnection in wheel speed sensor (RL) (OP)
Failure in wheel speed sensor (RL) system (OP) Transmission output shaft speed sensor
Disconnection in transmission output shaft speed sensor Disconnection in transmission output shaft speed sensor
Transmission output shaft speed sensor Transmission output shaft speed sensor Failure in transmission output shaft speed sensor Short circuit in buzzer output
Failure in auto suspension solenoid 1 output system (Disconnection, grounding fault, short circuit) (OPT) Failure in auto suspension solenoid 2 output system (Disconnection, grounding fault, short circuit) (OPT)
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HD465-7, HD605-7
Failure code DW72KZ DW73KZ DWNBK4
Failed section
Failure in kick-out solenoid output system (D_OUT3) (Disconnection, grounding fault, short circuit) Failure in hoist select valve output system (D_OUT5) (Disconnection, grounding fault, short circuit)
Failure phenomenon (Phenomenon/Contents of failure) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Not control (K4) Not control (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Not control (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Not control (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB)
Controller BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK TM TM TM TM TM TM TM TM
Action code E01 E03 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03
Shut-off valve
DWNBKA Disconnection in shut-off valve system DWNBKB Grounding fauit in shut-off valve system DWNBKY Short circuit in shut-off valve system DWNBMA Shut-off valve DX11K4 DX11KA DX11KB DX11KY DX11MA DX13KA DX13KB DX13KY DX17K4 DX17KA DX17KB DX17KY DX17MA DX18K4 DX18KA DX18KB DX18KY DX18MA DXH1KA DXH1KB DXH2KA DXH2KB DXH3KA DXH3KB DXH4KA DXH4KB
Electromagnetic proportional pressure reducing valve Disconnection in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Short circuit in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Grounding fault in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Electromagnetic proportional pressure reducing valve Disconnection in output circuit of hoist EPC valve (A_OUT3) Grounding fault in output circuit of hoist EPC valve (A_OUT3) Short circuit in output circuit of hoist EPC valve (A_OUT3) ASR proportional solenoid pressure reducing valve (Right) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) ASR proportional solenoid pressure reducing valve (Right) ASR proportional solenoid pressure reducing valve (Left) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP)
Disconnection in output circuit of lockup clutch solenoid
Short circuit in output circuit of lockup solenoid

Disconnection in output circuit of H clutch solenoid Short circuit in output circuit of H clutch solenoid Disconnection in output circuit of L clutch solenoid Short circuit in output circuit of L clutch solenoid Disconnection in output circuit of 1st clutch solenoid Short circuit in output circuit of 1st clutch solenoid
HD465-7, HD605-7
20-173
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Failure code DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXHHKA DXHHKB
Failed section
Disconnection in output circuit of 2nd clutch solenoid Short circuit in output circuit of 2nd clutch solenoid Disconnection in output circuit of 3rd clutch solenoid Short circuit in output circuit of 3rd clutch solenoid Disconnection in output circuit of R clutch solenoid Short circuit in output circuit of R clutch solenoid Disconnection in output circuit of 4th clutch solenoid Short circuit in output circuit of 4th clutch solenoid
Failure phenomenon (Phenomenon/Contents of failure) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB)
Controller TM TM TM TM TM TM TM TM
Action code E03 E03 E03 E03 E03 E03 E03 E03
a For details of the VHMS controller related failure codes not displayed on the machine monitor, see Troubleshooting VHMS control system. a Separate table: Detailed phenomena of L Series phenomenon codes (L*) Problem code
L0 L1 L2 L3 L4 L5 L6 L8 LC LH
Nature Fill signals on 2 or more channels for clutches not forming a set are input at same time Fill signal is ON when command current to ECMV is OFF Fuel pressure is higher than maximum set pressure Corresponding component cannot be controlled ON/OFF signals for 2 systems do not match Potentiometer signal and switch signal do not match Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch, etc. do not match operating condition or stopped condition of machine Analog signals for 2 systems do not match Speed signals for 2 systems do not match Fill signal is OFF when command current to ECMV is ON
a Failure codes with ( ) These failure codes are not recorded as fault history for either the electrical system or the mechanical system. a Controller codes and troubleshooting mode names The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting section are linked, so check the controller code for the failure code displayed, then go to the applicable troubleshooting mode. ENG: Troubleshooting of engine controller system (ENG MODE) TM: Troubleshooting of transmission controller system (TM MODE) BK: Troubleshooting of retarder controller system (BK MODE) MON: Troubleshooting of machine monitor system (MON MODE) VHMS: Troubleshooting for VHMS controller system (including payload meter system in VHMS) (VHMS mode)
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HD465-7, HD605-7
Procedure for switching to Service mode and screen display a When using Service mode, carry out the following special operation to switch the screen display. 1) Checking screen display With the machine monitor in the operator mode, check that the screen is one of the following displays: 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 display for the ID input (Fig. 1). [t] button and [<] button a If the buttons are held pressed for at least 5 sec, the whole screen will give no display, so check this condition, then release the buttons. 3) Inputting ID, confirming Operate the buttons to input the ID (Fig. 2). a ID: 6491 [>] button: Number at cursor goes up [<] button: Number at cursor goes down [ ] button: Number at cursor is confirmed [t] button: Returns to initial screen (see Note) Note: When the cursor is at the left side, the screen returns to the normal screen (operator mode). If the cursor is not at the left side, the cursor returns to the left side. a If the switch on the ID input screen is not operated for more than 60 seconds, the screen returns automatically to the normal screen. 4) Displaying menu initial screen After confirming all four digits of the ID, the menu initial screen of Service mode is displayed (Fig. 3). a Once the ID has been input and confirmed, it remains effective until the starting switch is turned OFF.
HD465-7, HD605-7
20-175
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5) Menu selection in Service mode Press the [>] or [<] buttons on the menu screen and the menus of Service mode are displayed endlessly in the following order (Fig. 4). a The menu is displayed in the places marked with [*]. [>] button: Goes on to next menu [<] button: Goes back to previous menu (1) ELECTRICAL FAULT: Fault history display function for electrical system (2) MACHINE FAULT: Fault history display function for mechanical system (3) REAL-TIME MONITOR: Machine data monitoring function (4) CYLINDER CUT-OUT: Reduced cylinder mode (5) TUNING: Adjustment function (6) MAINTENANCE MONITOR: Filter, oil replacement time setting function (7) INITIALIZE: Initialize function (exclusive function for factory) 6) Completion of mode, function When operating at any point in any function, it is possible to finish the mode or function by using any of the following methods. (1) When continuing operations in another mode or function: Press the [t] button and return to the mode screen to be used or menu screen to be used. a Note that if the [t] button is pressed on the YES/NO screen, the function will be executed. a If you return to the normal screen (operator mode) by mistake, repeat the procedure from Step 1) above (there is no need to input the ID again). (2) When completing all operations: Turn the starting switch OFF.
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HD465-7, HD605-7
9. Electrical system fault history display function (ELECTRIC FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. 1). a The total number of fault history items recorded in memory is displayed in the [ ] portion. 2) Fault history display With the menu selected, press the [ ] button and display the fault history recorded in memory (Fig. 2: example). [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the electrical system, the following data can be displayed (Fig. 3). 1: Record number (recorded up to a maximum of 20 items) A: Failure code (4-digit location code + 2-digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. a For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. a Note that with the fault history display function and failure code display function for the electrical system, the displayed data are partially different. a If no fault history are recorded, [0] is displayed on the display portion for 1, and [] is displayed on the display portion for A, 2, 3, and 4.
HD465-7, HD605-7
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4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history, the display switches to the other recorded fault history. [>] button: Goes on to data for next record number [<] button: Goes back to data for last record number 5) Deleting individual fault history i) Display the fault history to be deleted, then press the [ ] button once to display the individual item CLEAR screen (Fig. 4). [ ] button: Display CLEAR screen ii) Operate the buttons according to the explanation on the screen (Fig. 4). [<] button: Select YES [>] button: Select NO [t] button: Run a The data for an existing problem (flashing display) cannot be deleted. 6) Deleting all fault history i) Display the fault history, then press the [>] button or [<] button to display the ALL CLEAR menu (Fig. 5). ii) Press the [ ] button once to display the ALL CLEAR screen (Fig. 6). [ ] button: Run ALL CLEAR menu iii) Operate the buttons according to the explanation on the screen (Fig. 6). [<] button: Select YES [>] button: Select NO [t] button: Run a The data for an existing problem (flashing display) cannot be deleted.
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HD465-7, HD605-7
10. Mechanical system fault history display function (MACHINE FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. 1). a The total number of fault history items recorded in memory is displayed in the [**] portion. 2) Fault history display With the menu selected, press the [ ] button and display the fault history recorded in memory (Fig. 2: example). [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the mechanical system, the following data can be displayed (Fig. 3). 1: Record number A: Failure code (4-digit location code + 2digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. a For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. a Note that with the fault history display function and failure code display function for the mechanical system, the displayed data are partially different. a If no fault history are recorded, [0] is displayed on the display portion for 1, and [] is displayed on the display portion for A, 2, 3, and 4.
HD465-7, HD605-7
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4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history, the display switches to the other recorded fault history. [>] button: Goes on to data for next record number [<] button: Goes back to data for last record number 5) Deleting fault history (not permitted) a The fault history for the mechanical system cannot be deleted.
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HD465-7, HD605-7
11. Machine data monitoring function (REALTIME 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 following 2 types of display can be shown. 1st item independent display (for each controller) 2nd item simultaneous display (code input) 1) Menu selection Select the machine data monitoring function on the menu screen of Service mode (Fig. 1). 2) Display sub menu With the menu selected, press the [ ] button and display the initial screen of the sub menu (Fig. 2). [ ] button: Runs menu 3) Select sub menu If the [>] button or [<] button is pressed on the sub menu screen, the sub menu displays endlessly in the following order (Fig. 3). a The sub menu is displayed in the [*] portion. [>] button: Goes on to next menu [<] button: Goes back to last menu (1) MONITOR PANEL: Machine monitor system (2) TRANSMISSION: Transmission controller system (3) ENGINE: Engine controller system (4) BRAKE: Retarder controller system (5) 2 ITEMS: 2-item display
HD465-7, HD605-7
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4) Setting 1st item individual monitoring i) Select the controller system for monitoring on the sub menu screen (Fig. 4: example). ii) With the menu selected, press the [ ] button and display the monitoring data initial screen. [ ] button: Runs sub menu iii) Press the [>] button or [<] button to select the item for monitoring (Fig. 5: example). [>] button: Goes on to next item [<] button: Goes back to last item a Scroll the monitoring items to display in the internally set order. a If the button is kept pressed, the items will scroll at high speed. a To hold or cancel monitoring data: If the [ ] button is pressed during 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 monitoring On the 1st item individual monitoring screen, the following data are displayed (Fig. 6). A: Item display B: Monitoring code (5-digit) 1: Monitoring data (including unit) a For details, see MONITORING CODE TABLE.
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HD465-7, HD605-7
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 monitoring code for the 2nd monitoring item directly. [>] button: Number at cursor goes up [<] button: Number at cursor goes down [ ] button: Number at cursor is confirmed [t] button: Returns to code input screen
iv) When both of the monitoring codes have been confirmed, the screen switches to the 2nd item display screen (Fig. 9: example). a To hold or cancel monitoring data: If the [ ] button is pressed during monitoring, 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 monitoring On the 2nd item simultaneous monitoring screen, the following data are displayed (Fig. 10). A: Monitoring code 1 1: Monitoring data 1 (including unit) B: Monitoring code 2 2: Monitoring data 2 (including unit) a For details, see MONITORING CODE TABLE.
HD465-7, HD605-7
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Monitoring Code Table

MONITOR PANEL (Monitor panel system)
No.
Monitoring item Engine speed Engine coolant temperature (for high temperature) Torque converter oil temperature Brake oil temperature Fuel level sensor input resistance value Rheostat input voltage Operation status of front brake cut-out switch Operation status of ARSC switch (Operation status of ABS switch)
Item display ENG SPEED COOLANT TEMP H T/C OIL TEMP BRAKE OIL TEMP FUEL SENSOR RHEOSTAT F BK CUT SW ARSC SW ABS SW ASR SW CONN CHK 1, 2 SW1, SW2, SW3 SW5-1, SW5-2 SW5-3, SW5-4 SW6-1, SW6-2 SW6-3, SW6-4
Monitoring code
Display range 0 65535 0 160 0 160 0 160 0 150 0.0 51.0 ON/OFF ON/OFF ON/OFF ON/OFF
Unit rpm C C C z V
Status display Status display Status display Status display
1 2 3 4 5 6 7 8 9
01001 04104 30100 30200 04201 30300 37600 37700 37800 37900 30700 30800 30900 30901 30902 30903 31000 31001 31002
10 (Operation status of ASR switch) 11 Input status of connector check (1 & 2) 12 Setting status of rotary switch (SW1 & SW2 & SW3) 13 Setting status of dip switch (SW5-1 & SW5-2) 14 Setting status of dip switch (SW5-3 & SW5-4) 15 Setting status of dip switch (SW6-1 & SW6-2) 16 Setting status of dip switch (SW6-3 & SW6-4)
ON/OFF, ON/OFF Status display

0 F, 0 F, 0 F,
Status display
ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display ON/OFF, ON/OFF Status display
17 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2 18 Setting status of option selection connector (OP3 & OP4) OPTION 3, 4 19 Setting status of option selection connector (OP5 & OP6) OPTION 5, 6
a Note: The following monitoring items display data for 2 or 3 systems at the same time. No. 11: Input status of connector check (displays 2 items) No. 12: Setting status of rotary switch (displays 3 items at same time) No. 13: Setting status of dipswitch (displays 2 items at same time) No. 14: Setting status of dipswitch (displays 2 items at same time) No. 15: Setting status of dipswitch (displays 2 items at same time) No. 16: Setting status of dipswitch (displays 2 items at same time) No. 17: Setting status of option selection connector (displays 2 items at same time) No. 18: Setting status of option selection connector (displays 2 items at same time) No. 19: Setting status of option selection connector (displays 2 items at same time)
20-184
(10)
HD465-7, HD605-7
TRANSMISSION (Transmission controller system)

No.
Monitoring item Transmission service meter Transmission input shaft speed Transmission intermediate shaft speed Transmission output shaft speed Operation status of fill switch for Lo clutch Operation status of fill switch for Hi clutch Operation status of fill switch for 1st clutch Operation status of fill switch for 2nd clutch Operation status of fill switch for 3rd clutch
Item display
SERVICE METER
Monitoring code
Display range 0 65535 0 65535 0 65535 0 65535 ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 1020 0 2550 0 2550 0 2550 0 2550
Unit h rpm rpm rpm

Status display Status display Status display Status display Status display Status display Status display Status display
1 2 3 4 5 6 7 8 9
31100 31200 31300 31400 31510 31511 31512 31513 31514 31515 31516 31519 31600 31610 31601 31611 31602 31612 31603 31613 31604 31614 31605 31615 31606 31616 31609 31619 41801 41800 41806 41802
T/M SPEED: IN T/M SPEED: MID

T/M SPEED: OUT
FILL SW (L) FILL SW (H) FILL SW (1st) FILL SW (2nd) FILL SW (3rd) FILL SW (4th) FILL SW (R) FILL SW (L/U) ECMV H DIR ECMV H ECMV L DIR ECMV L ECMV 1 DIR ECMV 1 ECMV 2 DIR ECMV 2 ECMV 3 DIR ECMV 3 ECMV 4 DIR ECMV 4 ECMV R DIR ECMV R ECMV LU DIR ECMV LU FILL TIME H FILL TIME L FILL TIME R FILL TIME 1
10 Operation status of fill switch for 4th clutch 11 Operation status of fill switch for R clutch 12 Operation status of fill switch for lockup clutch 13 Command value of solenoid output current for Hi clutch 14 Sensed value of solenoid output current for Hi clutch 15 Command value of solenoid output current for Lo clutch 16 Sensed value of solenoid output current for Lo clutch 17 Command value of solenoid output current for 1st clutch 18 Sensed value of solenoid output current for 1st clutch 19 Command value of solenoid output current for 2nd clutch 20 Sensed value of solenoid output current for 2nd clutch 21 Command value of solenoid output current for 3rd clutch 22 Sensed value of solenoid output current for 3rd clutch 23 Command value of solenoid output current for 4th clutch 24 Sensed value of solenoid output current for 4th clutch 25 Command value of solenoid output current for R clutch 26 Sensed value of solenoid output current for R clutch
value of solenoid output current for lockup 27 Command clutch
mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA ms ms ms ms
28 Sensed value of solenoid output current for lockup clutch 29 Fill time of Hi clutch 30 Fill time of Lo clutch 31 Fill time of R clutch 32 Fill time of 1st clutch
HD465-7, HD605-7
20-185
(10)
No.
Monitoring item
Item display FILL TIME 2 FILL TIME 3 FILL TIME 4 FILL H FILL L FILL R FILL 1 FILL 2 FILL 3 FILL 4 THROTTLE POS
ENERG STRG 1,2
Monitoring code
Display range 0 2550 0 2550 0 2550 02 02 02 02 02 02 02 0.00 5.10
Unit ms ms ms
Status display Status display Status display Status display Status display Status display Status display
33 Fill time of 2nd clutch 34 Fill time of 3rd clutch 35 Fill time of 4th clutch 36 Fill status of Hi clutch 37 Fill status of Lo clutch 38 Fill status of R clutch 39 Fill status of 1st clutch 40 Fill status of 2nd clutch 41 Fill status of 3rd clutch 42 Fill status of 4th clutch 43 Input voltage of acceleration sensor 44 Operation status of emergency steering (1 & 2) 45 Input status of alternator terminal R 46 Input status of starting switch terminal C 47 Setting status of emergency escape switch 48 ECMV oil temperature 49 Torque converter oil pressure 50 Steering oil temperature 51 Output status of overrun prevention brake 52 Output status of DROOP MODE 2 (P/E) 53 Connector check input status (1 & 2) 54 Hydraulic tank level 55 Engine oil tank level 56 Transmission oil tank level 57 Electrolyte level 58 Radiator coolant level 59 Clogging status of air cleaner 60 Clogging status of transmission filter 61 Clogging status of hydraulic oil filter 62 Clogging status of engine oil filter 63 Judgment of acceleration at gear shifting point 64 Holding status of skip-shift 65 Gear shift mode status
41803 41804 41805 31501 31500 31506 31502 31503 31504 31505 31700 32100 04301 32300 32400 32500 32600 32700 35001 38100 30701 33000 38200 38300 40302 33100 33200 33300 33400 38400 38500 38600 38700
ALTERNATOR R KEY SW C ENERG TRAVEL ECMV OIL TEMP T/C OIL PRESS STRG OIL TEMP
OVERRUN BK DIR
ON/OFF ON/OFF ON/OFF 0 160 0.00 5.02
Status display Status display Status display
C MPa
OVERHEAT/NORStatus display MAL
ON/OFF ON/OFF
Status display Status display
DROOP MODE 2 CONN CHK 1,2 HYD OIL LEVEL ENG OIL LEVEL TM OIL LEVEL BATT LIQ LEVEL
COOLANT LEVEL
ON/OFF, ON/OFF Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display
CLOGGED/NOR- Status display MAL CLOGGED/NORStatus display MAL CLOGGED/NOR- Status display MAL CLOGGED/NOR- Status display MAL
AIR CLEANER T/M FILTER HYD OIL FILTER ENG OIL FILTER ACCELERATON TM SKIP SHIFT TM SHIFT MODE
QUICK/NRMAL Status display KEEP/NORMAL Status display 0F

Status display
20-186
(10)
HD465-7, HD605-7
No.
Monitoring item
Item display ROTARY SW 1,2 MACHINE SEL1 MACHINE SEL2 MACHINE SEL3
TM STATE CHECK
Monitoring code
Display range 0 F, 0 F GND/OPEN GND/OPEN GND/OPEN 00 FF
Unit
Status display Status display Status display Status display Status display
66 Setting status of rotary switch (SW1 & SW2) 67 Input status of model select wiring harness 1 68 Input status of model select wiring harness 2 69 Input status of model select wiring harness 3 70 1st update status for model rotary switch 71 Correction value of Hi clutch trigger 72 Correction value of Lo clutch trigger 73 Correction value of 1st clutch trigger 74 Correction value of 2nd clutch trigger 75 Correction value of 3rd clutch trigger 76 Correction value of 4th clutch trigger 77 Correction value of R clutch trigger
30801 02701 02702 02703 38800 38901 38900 38902 38903 38904 38905 38906
TRIGER MOD H TRIGER MOD L TRIGER MOD 1 TRIGER MOD 2 TRIGER MOD 3 TRIGER MOD 4 TRIGER MOD R
00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display 00000000 FFFFFFFF Status display
XXXXRYYY [3rd 10th digits of part No. from left are displayed] Example: If part No. is 7831-46R110, 3146R110 is displayed. XXXXRYYY [3rd 10th digits of part No. from left are displayed] Example: If part No. is 7831-46R110, 3146R110 is displayed.
78 Part No. of software (For main CPU)
TRANSM ROM 1
20204
Status display
79 Part No. of software (For sub-CPU)
TRANSM ROM 2
20205
Status display
a Note: The following monitoring items display data for 2 systems at the same time. No. 44: Actuation condition of emergency steering (displays 2 systems at same time) No. 53: Input status of connector check (displays 2 systems at same time) No. 66: Setting status of rotary switch (displays 2 items at same time)
HD465-7, HD605-7
20-187
(10)
ENGINE (Engine controller system)

No.
Monitoring item Engine speed Opening rate of acceleration sensor Fuel temperature Fuel (rail) pressure Fuel consumption Timing rail pressure Boost pressure Engine coolant temperature Engine oil pressure
Item display ENG SPEED THROTTLE POS FUEL TEMP

METRING PRESS
Monitoring code
Display range 0 8032 0.0 100 -40 210 0.00 9.99 0.0 999.9 0.00 9.99 0 300 -40 210 0 1000 -273.0 1735.0 0.0 125.0
Unit rpm % C MPa L/h MPa kPa C kPa C kPa
1 2 3 4 5 6 7 8 9
01002 31701 04203 37000 37300 37100 36500 04104 37200 37500 37400
FUEL RATE TIMING PRESS BOOST PRESS

COOLANT TEMP
ENG OIL PRESS AIR TEMP AIR PRESS
10 Temperature in intake manifold 11 Atmospheric pressure
20-188
(10)
HD465-7, HD605-7
BRAKE (Retarder controller system)

No.
Monitoring item Brake service meter

Command value of rear retarder EPC solenoid output current
Item display
SERVICE METER
Monitoring code
Display range 0 - 65535 0 1020 0 1020

0.00 5.10 (0 100)
Unit h mA mA V (%)
1 2 3 4 5 6 7 8 9
31101 33800 33801 33900 34000 34100 34300 34301 34400 34600 34700 34800 34900 34901 35000 35100 32300 30702 35500 35501 35700 39000 39100 34501 39200 39300 39301 32802 32803 39400 31704 37701
F BK OUTP DIR
Sensed value of rear retarder EPC solenoid output current F BRAKE OUTPUT
Retarder lever input (Voltage & conversion quantity) Input status of retarder lever validation switch (1 & 2)
RETARD LEVER RLV SW 1,2 RETARDER DUMP LEVER 1 DUMP LEVER 2 BODY POSITION BODY SEATING KICKOUT SOL SWV FOR HOIST

WORKING/ RELEASE
Operation status of retarder lever switch Input voltage of dump lever potentiometer 1 Input voltage of dump lever potentiometer 2 Input voltage of body positioner sensor
Status display
0.00 5.10 0.00 5.10 0.00 5.10 ON/OFF ON/OFF ON/OFF 0 1020 0 1020 ON/OFF ON/OFF ON/OFF
V V V
10 Input status of body seating switch 11 Output status of dump lever kick-out solenoid 12 Output status of dump select solenoid
13 Command value of dump EPC solenoid output current EPC HOIST DIR 14 Output current detection value for dump EPC solenoid EPC HOIST 15 Input status of overran command 16 Input status of service brake oil pressure switch 17 Input status of starting switch terminal C 18 Connector check input status (1 & 2) 19 Front accumulator oil pressure 20 Rear accumulator oil pressure 21 Clogging status of brake cooling filter 22 Inclination angle switch 23 Command of front brake cut 24 Hoist lower pressure 25 Auto suspension mode 26 Auto suspension solenoid 1 output 27 Auto suspension solenoid 2 output 28 Front suspension pressure (right) 29 Front suspension pressure (left) 30 Judgment of load 31 Accelerator sensor 32 Travel speed set with ARSC switch
mA mA
OVERRUN SIG
SERVICE BRAKE
KEY SW C CONN CHK 1,2 ACC OIL PRE F ACC OIL PRE R RETARD FILTER INCLINATION SW FBK CUT DIR HOIST PRESS
AUTO SUS MODE
0.00 50.26 0.00 50.26
MPa MPa
CLOGGED/NORStatus display MAL
ON/OFF ON/OFF 0.00 50.26
MPa
MEDIUM/SOFT/ Status display HARD
AUTO SUS DIR 1 AUTO SUS DIR 2 SUS PRESS (FR) SUS PRESS (FL) EMPTY OR LOAD
THROTTLE POS ARSC SET SP SW
ON/OFF ON/OFF 0.00 20.10 0.00 20.10 EMPTY/LOAD 0.00 3.10 0.00 3.10
MPa MPa
Status display
V V
HD465-7, HD605-7
20-189
(10)
BRAKE [Retarder controller system]

No.
Monitoring item
Item display ARSC STATUS

ARSC SET SPEED
Monitoring code
Display range ON/OFF 0 255 ON/OFF 0 1020 0 1020 0 1020 0 1020 ON/OFF ON/OFF 0.00 5.10 0.0 99.99 0.0 65535
0.0 65535 [0000 FFFF]
XXXXRYYY [3rd 10th digits of part No. from left are displayed] Example: If part No. is 7831-46R110, 3146R110 is displayed. XXXXRYYY [3rd 10th digits of part No. from left are displayed] Example: If part No. is 7831-46R110, 3146R110 is displayed.
Unit
Status display
33 ARSC command 34 Travel speed set with ARSC 35 ASR command 36 (ASR output (L) (Command value)) 37 (ASR output (L) (Sensed value)) 38 (ASR output (R) (Command value)) 39 (ASR output (R) (Sensed value)) 40 (ASR switch (R)) 41 (ASR switch (L)) 42 Steering angle 43 Steering angle speed 44 Wheel speed (RL) 45 Wheel speed (RR)
39500 39501 39600 39601

39602 39603 39604 39605 39606
km/h
Status display
ASR STATE ASR OUTP DIR L

ASR OUTPUT (L) ASR OUTP DIR R ASR OUTPUT (R) ASR SW (R) ASR SW (L) STRG ANGLE STRG ANG SPEED WHEEL SPEED RL WHEEL SPEED RR
mA
mA mA mA Status display Status display V
35400 35401 39700 39701
rad/s rpm rpm
46 Part No. of software (For main CPU)
BRAKE ROM 1
20206
Status display
47 Part No. of software (For sub-CPU)
BRAKE ROM 2
20207
Status display
a Note: The following monitoring items display data for 2 systems at the same time. No. 4: Retarder lever input (displays 2 types at same time; does not display unit for conversion %) No. 5: Input status of retarder lever validation switch (displays 2 systems at same time) No. 18: Connector check input status (displays 2 systems at same time)
20-190
(10)
HD465-7, HD605-7
VHMS (VHMS controller system)

No.
Monitoring item Exhaust temperature (F) Exhaust temperature (R) Engine oil temperature Ambient temperature Blow-by pressure Payload Suspension pressure (FR) Suspension pressure (FL) Suspension pressure (RR)
Item display
EXHAUST TEMP F EXHAUST TEMP R
Monitoring code
Display range 200 950 200 950 0 +180 -30 +100 0.0 20.0
0.0 6553.5 (*) 0.0 20.10 (*) 0.0 20.10 (*) 0.0 20.10 (*) 0.0 20.10 (*) -0.42 +0.44 (*) ON/OFF (*) ON/OFF (*) 08 (*)
Unit C C C C kPa
t (metric ton or short ton)
1 2 3 4 5 6 7 8 9
42600 42601 42700 37501 42800 42200 32804 32805 32806 32807 32901 42300 42500 42400
ENG OIL TEMP AIR TEMP BLOW PRESS PAYLOAD SUS PRESS (FR) SUS PRESS (FL) SUS PRESS (RR) SUS PRESS (RL) INCLINOMETER FLOAT SIG SHIFT LEVER N TRUCK STATUS
MPa MPa MPa

MPa rad Status display Status display Status display
10 Suspension pressure (RL) 11 Angle sensor 12 FLOAT signal 13 Gearshift lever N signal 14 Machine status
a The (*) mark in the data display range column shows the case when the PLM is not set up.
HD465-7, HD605-7
20-190-1
(10)
12. Adjustment function (TUNING) Through the transmission controller, the machine monitor can carry out the the adjustment function to correct the difference in operating feeling to a constant level caused by the the individual differences in the ECMV. It can also carry out the selfadjusting 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 replaced When the transmission controller has been replaced When an abnormality has occurred in the power train speed sensor and it has been repaired (for details, see the failure code in the chart on the right) When an abnormality has occurred in the transmission oil temperature sensor and it has been repaired (for details, see the failure code in the chart on the right) When the transmission oil filter has become clogged and it has been repaired (for details, see the failure code in the chart on the right) For the adjustment operation, operate the machine monitor and machine itself, and carry out the following items in order (Fig. 2). a ( ) indicates the menu to use for the adjustment operation. (1) Adjusting individual difference of valve (02: ECMV TUNING AUTO) (2) Resetting gearshifting feeling stabilized learning data (01: TM TRIGGER) (3) Gearshifting feeling stabilized initial learning (monitoring function) a The MANUAL menu of [02: ECMV TUNING] is a special function for the factory and is not used for service.
Failure code DLF1KA DLF1LC DLF2KA DLF2LC DLT3KA DLT3LC DGF1KA 15B0NA
Component name Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission output shaft R speed sensor Transmission valve oil temperature sensor Transmission oil filter
HD465-7, HD605-7
20-191
(5)
Preparatory work: Adjusting ECMV oil temperature a It is necessary to carry out the adjustment operation at the specified oil temperature, so check that there is no abnormality on the machine and adjust the ECMV oil temperature as follows. 1) Start the engine. 2) Display [ECMV oil temperature] with machine data monitoring function. (Fig. 1). TRANSMISSION No. 48 the
3) Raise ECMV oil temperature to 70 80C by raising engine speed. 4) Keep engine speed in low idle for 3 minutes. Before carrying out adjustment, be sure to check that ECMV oil temperature is kept within 70 80C.
20-192
(9)
HD465-7, HD605-7
Adjustment operation (1): Adjusting individual difference of valve a See Preparatory work and check that the ECMV oil temperature is at the specified temperature. a The adjustment operation is carried out automatically four times for the Lo, Hi, R, 1st, 2nd, 3rd and 4th valves. 1) Set the machine to the following conditions. Parking brake switch: PARKING AISS LOW switch: LOW Gearshift lever: N position Engine: Low idle Accelerator pedal: OFF (released) 2) Operate the machine monitor and display the adjustment menu screen (Fig. 4). Adjustment menu: 02: ECMV TUNING AUTO 3) Check the condition of the machine again, press the [ ] button, and start the adjustment operation (Fig. 5). [ ] button: Runs adjustment menu a The adjustment is carried out consecutively four times for the applicable clutches and displays a screen like the one shown on the right. a For each adjustment operation, the result is displayed as normal or abnormal, so take action according to the display (Fig. 6). If [4-4 OK] is displayed: The adjustment operation has been completed correctly. (When the starting switch is turned OFF, the adjusted value is recorded in the controller.) If [NG 1] (Outside compensation condition) is displayed: Adjust the ECMV oil temperature correctly, check the set conditions of the machine again, then repeat from Step 1). If [NG 2] (No fill) is displayed: Carry out troubleshooting for failure codes [15S[ ]MA] [DDT[ ]KA], and if it is found to be 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).
No. 1 2 3 4 5 6 7
Valve Lo Hi R 1st 2nd 3rd 4th
1st time 2nd time 3rd time 4th time IP L-1 IP H-1 IP R-1 IP 1-1 IP 2-1 IP 3-1 IP 4-1 IP L-2 IP H-2 IP R-2 IP 1-2 IP 2-2 IP 3-2 IP 4-2 IP L-3 IP H-3 IP R-3 IP 1-3 IP 2-3 IP 3-3 IP 4-3 IP L-4 IP H-4 IP R-4 IP 1-4 IP 2-4 IP 3-4 IP 4-4
HD465-7, HD605-7
20-193
(10)
Adjustment operation (2): Resetting gearshifting feeling stabilized learning data 1) Operate the machine monitor and display the initial menu screen (Fig. 7). Initial menu: 01: TM TRIGGER a The present initial status is displayed on the bottom line of the screen. Initializing completed: INITIAL STATUS Initializing not performed: TUNED a With the transmission adjustment, the learning data is initialized from the following operation, 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 display (Fig. 8). [<] button: Select YES [>] button: Select NO [t] button: Run a After carrying out initializing, check that INITIAL STATUS is displayed on the bottom line of the screen.
20-194
(1)
HD465-7, HD605-7
Adjustment work (3): Initial learning of stabilization of gear shifting feel a Referring to PREPARATION WORK, check that the ECMV oil is at the specified temperature. Perform the adjustment work in a place wide sufficiently for travel, taking care of the safety around the machine. a When performing the adjustment work by driving the vehicle actually, perform it on finished flat ground, as long as possible. 1) Display R CLUTCH FILL STATE with the machine monitoring function (Fig. 10). No. 38 of TRANSMISSION FILL R: Fill state of R clutch 2) Run the engine at low idle and hold the gearshift lever in the N position for 10 seconds, and then operate the gearshift lever in the following order. a Operation of gearshift lever: N o R o N 3) Check the fill state with the monitoring display. a If "0" is displayed, go the next step. a If "1" is displayed, repeat step 2) until "0" is displayed. a After Step 2) is repeated 3 times, if "0" is still not displayed, display R CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 250 msec or shorter, go to 4). (2) If the fill time is 900 msec or longer, return to 1) and repeat step 2) until the fill state of the R clutch becomes "0". No. 31 of TRANSMISSION FILL TIME R: Fill time of R clutch (Fig. 11) a If the above condition is still not satisfied after the steps are repeated 5 times, the ECMV may be defective. In this case, replace the ECMV.
HD465-7, HD605-7
20-195
(10)
4) Set the gearshift lever in the 6 position. Run the engine at full throttle and shift up the gear to F6. 5) Drive the machine in F6 for 10 seconds, and then release the accelerator pedal and shift down the gear to F1 by coasting run. a Shifting down: F6 o F5 o F4 o F3 o F2 o F1 a Do not operate the brake during coasting run. 6) Display 4TH CLUTCH FILL STATE, 2nd CLUTCH FILL STATE, and 1st CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. 12, Fig. 13, and Fig. 14). No. 42 of TRANSMISSION FILL 4: Fill state of 4th clutch No. 40 of TRANSMISSION FILL 2: Fill state of 2nd clutch No. 39 of TRANSMISSION FILL 1: Fill state of 1st clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 4) and 5) until "0" is displayed for the all clutches. a After steps 4) and 5) are repeated 3 times, if "0" is still not displayed as the fill state of the 1st clutch, display 1ST CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 250 msec or shorter, go to 7). (2) If the fill time is 550 msec or longer, return to 4) and repeat steps 4) and 5) until the fill state of the 1st clutch becomes "0". No. 32 of TRANSMISSION FILL TIME 1 : Fill time of 1st clutch (Fig. 15) a If the above condition is still not satisfied after the steps are repeated 6 times, the ECMV may be defective. In this case, replace the ECMV.
20-195-1
(7)
HD465-7, HD605-7
7) Set the gearshift lever in the 3 position. Run the engine at full throttle and shift up the gear to F3. 8) Stop the machine and display HI CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 16). No. 36 of TRANSMISSION FILL H: Fill state of Hi clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 7) and 8) until "0" is displayed. a After steps 7) and 8) are repeated 3 times, if "0" is still not displayed as the fill state of the Hi clutch, display HI CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 200 msec or shorter, go to 9). (2) If the fill time is 550 msec or longer, return to 7) and repeat steps 7) and 8) until the fill state of the Hi clutch becomes "0". No. 29 of TRANSMISSION FILL TIME H : Fill time of Hi clutch (Fig. 17) a If the above condition is still not satisfied after the steps are repeated 5 times, the ECMV may be defective. In this case, replace the ECMV.
HD465-7, HD605-7
20-195-2
(7)
9) Display LO CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 18). No. 37 of TRANSMISSION FILL L: Fill state of Lo clutch 10) Set the gearshift lever in the 4 position. Run the engine at full throttle and shift up the gear to F3. a Take care not to shift up the gear to F4. If the gear has been shifted to F4, repeat the step from starting. 11) Drive the machine in F3 for 5 seconds, and then shift up the gear to F4 with the engine at full throttle. 12) While the machine is traveling in F4, press control switch [U] to keep displaying the machine monitoring function. 13) Stop the machine and display LO CLUTCH FILL STATE and 3RD CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. 19). a Judge the fill state of the Lo clutch by the value displayed and held during travel at F4. Once holding is reset, the value is updated. No. 41 of TRANSMISSION FILL 3: Fill state of 3rd clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 9) 13) until "0" is displayed for both clutches. a After steps 9) 13) are repeated 6 times, if "0" is still not displayed, the ECMV may be defective. In this case, replace the ECMV. a The display keeping function of the machine monitoring function is reset automatically when any switch is operated. a If the starting switch is turned OFF or control switch [ t] is pressed 3 times, the machine monitoring function screen disappears and the ordinary screen appears.
20-195-3
(7)
HD465-7, HD605-7
13. Filter, oil replacement time setting function (MAINTENANCE MONITOR) The machine monitor can set the maintenance interval for filters and oil, which form the base for the filter and oil replacement time and display. 1) Menu selection Select Filter, oil replacement time setting function on the menu screen of Service mode (Fig. 1). 2) Selecting filter, oil replacement time setting item i) With the menu selected, press the [ ] button and display the initial screen of the set item (Fig. 2). [ ] button: Runs menu ii) Press the [>] or [<] buttons to select the item to be set. [>] button: Goes on to next item [<] button: Goes back to last item a The set items are displayed endlessly in the internal set order (for details, see Table 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 displayed (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 function a The presently set interval is displayed on the screen.
20-196
(9)
HD465-7, HD605-7
i)
ii)
Operate the buttons to input the interval (Fig. 4). [>] button: Number at cursor goes up [<] button: Number at cursor goes down [ ] button: Number at cursor is confirmed [t] button: Returns to item selection screen a The time must always be input with four digits. For numbers of less than four digits, input 0s at the beginning. When all the interval times are confirmed, the change confirmation screen is displayed, so operate the buttons according to the screen display (Fig. 5). [<] button: Select YES [>] button: Select NO [t] button: Run
Table of filter and oil replacement time set items

No. 1 2 3 4 5 6 7 8 9 10 11 12 Fuel filter Engine oil filter Engine oil Transmission oil filter Corrosion resistor Torque convertor, transmission, brake oil Brake oil filter Brake cooling oil filter Hydraulic filter Differential case oil Final drive oil Hydraulic oil Item Code 03 02 01 13 06 24 14 16 04 11 08 10 Display FUEL FILT ENG FILT ENG OIL TM FILT CORR RES TC/TM/BK OIL BK OIL FIL BK C FIL HYD FILT DIFF OIL FNL OIL HYD OIL Replacement time 0500 0500 0500 0500 1000 1000 1000 1000 2000 2000 2000 4000
HD465-7, HD605-7
20-197
(1)
14. Snap shot function a For this function, see "Execution of PM clinic using manual snap shot (Another name: Quick PM)" (Drawing No. WJ021D060) (Fig. 1).
15. PLM setting function a This function is applied to "PLM having VHMS" (only when the option is set). Various items of the "PLM having VHMS" are displayed and set with this function.
1) Setting of travel distance to recognize completion of loading Input a travel distance to recognize completion of loading by pressing the following buttons (Fig. 3). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Stop inputting number. a The setting range is 0 255 m (0.0 0.158 miles). If the set value is too small, the system may recognize that loading is completed while the dump truck is still being loaded. 2) Correction of calculation of payload Since this function affects the accuracy directly, execute the following procedure securely. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. Accordingly, secure travel distance for this purpose.
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HD465-7, HD605-7
i)
ii)
The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment. Accordingly, perform the following procedure very carefully. This function is used to match the calculation result to the indication of the load meter to be used. It does not always heighten the absolute accuracy. Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper, etc.) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. (1) Select "EMPTY WEIGHT" (Fig. 4). [>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". [U] button: Enter the selection. (After selecting, go to Fig. 5.) [t] button: Return to the previous screen. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected (See Fig. 11). Check the unit of the input value. a The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC) --- metric ton (SHORT) ---- short ton (2) Check that measurement of the weight of the empty dump truck has been completed. a Display on the screen (Fig. 5) [U] button: Check that measurement has been completed and go to the next step. [t] button: Return to the previous screen.
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(3) Input the measured weight of the empty dump truck (Fig. 6). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. a Inputtable range HD465-7: 43.6 [t] (Operating weight) 15% (metric ton) HD605-7: 46.8 [t] (Operating weight) 15% (metric ton) (4) Check the input value (Fig. 7). [>] button: Select "YES". [<] button: Select "NO". [t] button: Enter.
(5) Move the dump truck to a place where you can drive it. a Display on the screen (Fig. 8) [U] button: After getting ready for drive, press this button and start driving the dump truck. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. [t] button: Return to the screen for inputting values.
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HD465-7, HD605-7
(6) Display the progress of measurement (Fig. 9). [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. a As measurement is executed, the number of " * " increases. When measurement is finished, the next screen appears automatically. iii) Load the dump truck to measure the weight of the fully loaded dump truck (Fig. 10). [t] button: Return to the menu screen. a When loading is started, the menu s cr een app ears automati cal ly. When indicating the current load for reference while the dump truck is being loaded, go out of "Service mode" temporarily and return to "Display of load/integrated odometer". On this screen, you can check the current load. iv) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper, etc.) v) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes. (1) Select "LOADED WEIGHT" (Fig. 11). a For the method of displaying the following screen, see the steps up to ii) - (1). [>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". [U] button: Enter the selection. [t] button: Return to the previous screen. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected (See Fig. 11). Check the unit of the input value. a The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC) --- metric ton (SHORT) ---- short ton
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(2) Check that measurement of the weight of the fully loaded dump truck has been completed. a Display on the screen (Fig. 5) [U] button: Check that measurement has been completed and go to the next step. [t] button: Return to the previous screen.
(3) Input the measured weight of the fully loaded dump truck (Fig. 6). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. a Inputtable range HD465-7: A1 (A1 x 0.25) (metric ton) However, A1 = {43.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 (A2 x 0.25) (metric ton) However, A2 = {46.8 [t] (Operating weight) + 63 [t] (Load capacity)} (4) Check the input value (Fig. 7). [>] button: Select "YES". [<] button: Select "NO". [t] button: Enter.
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HD465-7, HD605-7
(5) Move the dump truck to a place where you can drive it. a Display on the screen (Fig. 8) [U] button: After getting ready for drive, press this button and start driving the dump truck. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. [t] button: Return to the screen for inputting values. (6) Display the progress of measurement (Fig. 9). [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. a As measurement is executed, the number of " * " increases. When measurement is finished, the next screen appears automatically. vi) Dump the load in the dump area (Fig. 12). [t] button: Return to the menu screen. a If the load is dumped with the dump lever, the menu screen appears automatically. If the load is dumped normally, correction is finished. 3) Correction of level of inclination sensor i) Move the dump truck to a level place. ii) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. (1) Enter value of (F) (Fig. 13). [U] button: Enter the flashing value. [t] button: Return to the menu screen. a The current standard level value is displayed on the upper line. The clinometer value (F) at the current position flashes. Enter it when it is stabilized.
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(2) Turn the dump truck 180 degrees (Stop it in the opposite direction). (3) Enter value of (R). [U] button: Enter the flashing value. [t] button: Return to the menu screen. a The current standard level value is displayed on the upper line. The clinometer value at the current position flashes. Enter it when it is stabilized.
(4) Enter the standard level value (Fig. 15). [>] button: Select "YES". [<] button: Select "NO". [t] button: Enter.
4) Setting of criterion of maximum travel speed Input a criterion of the maximum travel speed by pressing the following buttons (Fig. 16). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Stop inputting number. a The setting range is 0 99 km/h (0 62 MPH). (Default: 99 km/h)
5) Setting of payload to recognize start of loading Input a payload to recognize start of loading by pressing the following buttons (Fig. 17). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Stop inputting number. a The setting range is 0 25.5%. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below (on the next page).
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HD465-7, HD605-7
If the value is reduced, start of loading may be recognized wrongly. If the value is increased and a loader having a small-capacity bucket is used, the forecast function of the outside indicator lamps and the MMS communication may not operate normally. 6) Setting of indication range of outside indicator lamps Input an indication range of the outside indicator lamps by pressing the following buttons (Fig. 19). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Stop inputting number. a The setting range is 0 130% of the load capacity. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp), however. 7) Setting of OFFSET function Input an offset range by pressing the following buttons (Fig. 20). [>] button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [U] button: Enter number at cursor. [t] button: Stop inputting number. a The setting range is -5.0 +5.0 [t]. Check the unit of the input value on the previous menu screen (Fig. 21). a The unit is indicated in the ( ) on the right side of the input value [t]. (METRIC) --- metric ton (SHORT) ---- short ton
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8) Selection of method of entering saved payload i) Select the method of entering the saved payload (Fig. 22). [>], [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped. [U] button: Enter the selected method. [t] button: Return to the menu screen. ii) Enter the selected method (Fig. 23). [>] button: Select "YES". [<] button: Select "NO". [t] button: Enter.
16. Initialize function (INITIALIZE) (exclusive function for factory) a This is a special function for the factory and is not used for service.
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BASIC PRECAUTIONS
BASIC PRECAUTIONS
1. Handling machine, safety, inspection and maintenance For details of safety items, operation, inspection, and maintenance of the machine, see the Operation and Maintenance Manual for the machine. 2. Handling monitoring system Always obey the following precautions when handling the monitoring system. 1) When disassembling, repairing, or modifying the machine or system, follow the instructions in the manual. 2) Do not touch the system (equipment) when operating the machine. 3) Do not damage or get the wiring harnesses, connectors, or sensors of the system (equipment) caught or pulled by force. This may cause short circuits or disconnections that will lead to failure or fire on the machine or system (equipment). 4) Do not get water, dirt, or oil on the system (equipment). 3. Permanent power source for VHMS (battery direct power source) 1) Meaning and need of permanent power source The VHMS has the function of checking and collecting data on the condition of the machine from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Therefore, its power supply is differentfrom many of the electronic equipment and electrical parts. For the system to provide the above functions, it is necessary to have a power supply
that is connected directly to the battery and always supplies electricity (permanent power source) in addition to the power source (switch power source) that is cut when the starting switch is turned OFF or the engine is stopped. Because this switch power source and permanent power source are provided, the period needed for collecting data is clearly known and it becomes possible to store this data in the internal memory. In other words, the VHMS uses the permanent power source to save to memory the data accumulated from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Then the VHMS controller itself turns off the permanent power source. 2) Precautions when turning the permanent power source OFF When the starting switch is turned OFF, the power supply is maintained for at least 3 minutes (the VHMS system shut-down time: the time taken for the VHMS system to save the data to memory and switch off), and then the permanent power source is turned OFF. If the VHMS system shut-down time is shorter than 3 minutes, the accumulated data may be damaged. i) When removing VHMS from permanent power source When removing the VHMS from the permanent power source (for example, when carrying out repairs), check that the monitor display (7-segment LED in the diagram below) of the VHMS controller is out.
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HD465-7, HD605-7
BASIC PRECAUTIONS
ii) When installing battery isolator or other battery shut-down device a) Basic connections It is a basic assumption that the engine stop switch is a type that will not shut off the permanent power source when the engine is stopped. b) When safety regulations for user make it impossible to avoid shutting down all electric power Install a battery isolator so that the permanent power source is kept in the specified condition for at least 3 minutes after the starting switch is turned OFF before the permanent power source is shut down. If there is no timer, wait for at least 3 minutes before turning off the permanent power source. If the above shut-down time is shorter than 3 minutes, the accumulated data may be damaged. 4. Precautions when VHMS power source is ON For the first few seconds after the power is switched ON, the VHMS controller carries out the initial check (LEDs flash). Do not carry out any of the following operations until the initial check is completed. Operation of manual snapshot switch Downloading from PC (Check that the LEDs are displaying the aggregate numerals in turn before operating.) 5. Precautions when replacing VHMS and transmission controller 1) Before starting replacement i) Download VHMS data When the VHMS controller is replaced, the data collected up to that point is lost, so be sure to download the accumulated data before starting the replacement operation. Next, send the accumulated data to web care. For details of the method of downloading, see the separate instruction manual for the technical analysis tool box.
ii) Specified method of shutting down VHMS power source a) Use the starting switch to turn the normal power source OFF b) Maintain the permanent power source in the specified condition for at least 3 minutes. c) Turn the permanent power source (battery direct) OFF.
HD465-7, HD605-7
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BASIC PRECAUTIONS
2) Method of replacement, action after replacement When replacing the VHMS controller, be careful not to subject the VHMS controller or wiring harnesses to any excessive force or impact, and carry out the initial setup. For details, see the separate instruction manual for the technical analysis tool box. 6. Handling communications controller (ORB Orbcomm) 1) The ORB controller must be used. If the ORB controller is not used, it is impossible to carry out the request to open communications before starting to use. If the control power is turned on before completing the request, the transmission will be unauthorized and there will be problems with the communications system. If there are any problems or any part is unclear, please contact Komatsu or the person responsible for operation. 2) Finally, turn on the ORB power ON (connect the connector). After the VHMS controller confirmation is completed, connect the ORB controller connector (ORB-A, ORB-B).
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OUTLINE
OUTLINE
a It is also possible to add this system to a machine that has already been shipped. 1. Basic structure (1)
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OUTLINE
2. Basic structure (2)
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OUTLINE
HD465-7, HD605-7
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OUTLINE
3. Position of equipment Install monitoring controller (VHMS controller) (1) on the machine, and collect the operation data for the engine, transmission, and PLM. 1) Data collection function i) Data from connected sensors Blow-by pressure {sensor (2)} Engine oil temperature {sensor (3)} Exhaust gas temperature {sensor (4)} Ambient temperature {sensor (5)} ii) Data from controller mounted on machine Engine speed Fuel injection amount Engine oil pressure Data from transmission controller Data from retarder controller Data from PLM II controller SMR (service meter) 2) Saving data The above data is saved to memory.
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OUTLINE
3) External communication function Connect the PC (personal computer) to the VHMS controller, download the data, and transmit the data through the Internet. Send the data automatically from remote areas through the communications satellite (ORB). (6): Ground level download connector (7): Download connector inside cab (8): Communications antenna/pole Antenna mount: Thread tightener (LT-2)
HD465-7, HD605-7
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SETTING UP VHMS CONTROLLER

1. Setting up VHMS controller In the following cases, always carry out the setup. 1) When making the initial installation of the VHMS system 2) When replacing or overhauling the following components VHMS controller Engine Transmission PLM II (option) When carrying out the setup, the following are needed 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) For details of the setup method, see the instruction manual for the technical analysis tool box (for service). The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. Or contact Komatsu.
2. Setting items VHMS: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Calendar (date, time, time difference from GMT, summer time (daylight saving time)) 2) Machine model, Serial No., variation code 3) Engine model, Serial No. 4) Transmission Serial No. For details of the method of setting PLM II and VHMS with PLM function, see the separate PLM instruction manual. 1) Time of the start of data collection 2) Data collection unit (day) Opening communications with Orbcomm: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Communications method (stop/start, interval, transmission time) 2) Time of PLM data collection 3) Country code for communications controller (GCC)
3. Setup flow (outline)

Procedure 1 Method (specific content, points to remember, etc.) Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal
Check for generation of errors Start setup tool

Setting up VHMS
Turn starting switch ON (starting switch ON)
Calendar (data, time, time difference from GMT, summer time

2
Machine model, Serial No., variation code Engine model, Serial No. Transmission Serial No. Time of start of data collection Data collection unit (day) Saving settings Checking VHMS functions Performing test (quick PM) Downloading Checking data (content of data) Checking operation of Orbcomm Setting up communications
(need for communications file, communications frequency, GCC code)
(daylight saving time))
3 4 5 6
Setting up PLM function or PLM II (when the PLM function is available or machine is PLM II specification) Starting switch OFF (starting switch OFF) Starting switch ON (starting switch ON) Start engine Test (quick PM) Starting switch OFF
Check for errors Start setup tool
Starting switch ON (starting switch ON)
Starting switch OFF (starting switch OFF)
Setup completion report, content of setup (data), sending checksheet Sending download data
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4. Checking operation, actuation a Check the functions of the VHMS system as follows.
Start
Turn starting switch to [ON] position Display Normal Engine, transmission controllers show past errors, then give [00] display (no error exists) No display VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display Display Normal
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position Display Normal Engine, transmission controllers show past errors, then give [00] display (no error exists) No display Abnormality in machine syastem See machine shop manual VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display Possible abnormality in VHMS controller Display Normal
5. Collection of data a If there is no abnormality in the system, the machine will operate and the operation data for the machine will automatically be saved by the VHMS controller.
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COLLECTION, TRANSMISSION OF DATA

1. Collection of data 1) Downloading with PC (personal computer) <Necessary tools> PC (personal computer) VHMS analysis tool (software) (799-608-3211) Download cable (799-608-3220) When using a PC to download the collected data, send the data to the file server in the computer center by e-mail (Internet). (There are limitations to the capacity of satellite communications, so use this method to send all the data.) 2. Setup flow (outline)
Procedure Turn starting switch ON (starting switch ON) Check for generation of errors Start setup tool Setting up communications Method (specific content, points to remember, etc.) Check that no error is generated by VHMS controller or other controller If there is any error, repair or correct to return condition to normal Checking satellite communications data, setting communications frequency Setting GCC code
a For details of downloading and sending the data, see the instruction manual for the technical analysis tool box (for service). 2) Automatic transmission by communications satellite (machines with Orbcomm specification) Error data and other specified data are automatically sent by communications satellite to the file server in the computer center.
2 3
Starting switch OFF (turn key to OFF) Saving set values Reporting completion of setup
3. Carrying out quick PM a For details, see TESTING AND ADJUSTING, Performing PM clinic using manual snapshot. To collect data under the normal working conditions, and to collect data when operating under such conditions as torque converter stall or high idle, carry out the quick PM (equivalent to PM clinic) before downloading with the PC. 4. Method of downloading with PC (personal computer) To ensure safety, stop the machine on level ground and put chocks under the tires to prevent the machine from moving. When turning the starting switch ON, check that the parking brake is ON and that the gearshift lever is at the N position. Sound the horn to warn people in the surrounding area before starting the engine. a For details of the method of using the PC, see the instruction manual for the technical analysis tool box (for service). <Preparatory work> Prepare a PC for downloading and a download wiring harness. a The download connectors are provided in 2 places: rear of assistant's seat inside cab (7) and behind front left tire of machine (6).
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<Downloading from connector inside cab> 1) Remove the connected wiring harness and install the download cable. 2) Connect the other end of the download wiring harness to the PC. 3) Turn the machine starting switch ON, check that the monitor controller is working, then download to the PC. a To check that the VHMS controller is working, check that the VHMS controller starts up, LEDs flash (see diagram below), and aggregate numerals are displayed in order. 4) When [complete] is displayed on the download PC, the download operation is completed. 5) Turn the machine starting switch OFF, then turn the PC power OFF, remove the download cable, and return the wiring harness to its original condition.
<Downloading from ground level connector> 1) Remove the clamp at the top of the download box. 2) Use the engine key to open the cover at the front of the box. 3) Remove the cap of the download connector and install the download cable. 4) When turn (wake-up) switch (10) is turned, the VHMS is actuated and pilot lamp (11) lights up. 5) Check that pilot lamp (11) is lighted up, then carry out the PC download. 6) When [complete] is displayed on the download PC, the download operation is completed. 7) Return the turn switch to its original position, remove the download cable, then install the cap. 8) Check that pilot lamp (11) is out, then close the box cover. If the turn switch is not off, the cover will not close. 9) Turn the engine key and lock the front cover. Close the clamps at the top of the box also.
4. Types of data collection files 1) Index file : This records the common data for the machine model, serial No., and service meter (SMR). 2) VHMS history : This records changes in the VHMS. 3) Machine history : This records the actual engine operation data. 4) Fault history : This records errors that occurred in order of occurrence. 5) Trend analysis : This records the maximum or minimum values for each measurement device at the specified intervals. (See Table 1) 6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures. (see Table 2) 7) Snapshot : This records the data for a specified time before and after the occurrence of an error (see Table 3.1, 2) 8) Load map : This records the frequency of the applicable area, taking the engine speed and fuel injection amount as the axes 9) Cycle interval : This records the aggregate frequency of the changes in engine speed 10) Running area : This records the operation distribution for each area on the engine performance graph 11) Running direction : This records the track of movement for each area on the engine performance graph 12) Transmission shift change map: This records the transmission gearshift data 13) Transmission fill time trend : This records the transmission clutch engagement time data (See table 4) 14) Payload data (if equipped) : This records the payload meter data 15) Payload data cycle (if equipped) : This records the operating cycle data for the machine
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TREND DATA ITEMS Table 1: Trend analysis data

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 SMR Calendar Engine speed max. Blow-by press. max. F. Exh. temp. max. R. Exh. temp. max. E. oil press. max. E. oil P. L min. E. oil P. H min. Eng. oil temp. max. Fuel rate Cool temp. max. Cool temp. min. Ambient temp. max. Ambient temp. ave. Ambient temp. min. Atmos. press. ave. F. brake P. max. R. brake P. max. Item Service meter Calendar Engine speed (max.) Blow-by pressure (max.) Front engine exhaust temperture (max.) Rear engine exhaust temperture (max.) Engine oil pressure (max.) Engine oil pressure at low idle (min.) Engine oil pressure at high idle (min.) Engine oil temperature (max.) Fuel consumption rate (average) Engine coolant temperature (max.) Engine coolant temperature (min.) Ambient temperature (max.) Ambient temperature (average) Ambient temperature (min.) Atmospheric pressure (average) Front brake oil pressure (max.) Rear brake oil pressure (max.) Content Unit h y/m/d h:m:s rpm mmAq deg.C deg.C kg/cm2 kg/cm2 kg/cm2 deg.C Liter/h deg.C deg.C deg.C deg.C deg.C hPa kg/cm
2
Data collection point
Remarks
Engine controller Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor Engine controller Engine controller Engine controller Engine oil temperature sensor Engine controller Engine controller Engine controller Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller Retarder controller Retarder controller
Maximum value within set trend data (Every 20 hours) See as below
kg/cm2
Table 2: Machine trend data

No. 1 2 3 4 SMR Calendar T/C oil temp. 120 T/C oil temp. 130 T/C oil temp. 140 Rtrdr. oil temp. T120 Rtrdr. oil temp. T130 Rtrdr. oil temp. T140 Item Service meter Calendar Time of use for each torque converter oil temperature sec. Time of use for each retarder oil temperature Retarder controller Content Unit h y/m/d h:m:s Transmission controller Data collection point Remarks
Table 3.1 Observation items (trigger items) for auto snapshot

No. 1 2 3 4 5 6 7 8 9 Content Failure code No. 11 12 13 14 15 16 17 18 19 20 Content Problem with No. 2 clutch Problem with No. 3 clutch Problem with No. 4 clutch Problem with engine speed senser Overheating of water Overheating of fuel Overheating of torque converter Overheating of rear brake oil Overrun Abnormal drop in engine oil pressure Failure code 15L0MW(b025) 15M0MW(b026) 15N0MW(b027) C115KZ C151NS C261NS B@CENS(A0d2) B@C7NS(A0d4) A00N1(n201) C143ZG No. 1,2,3 cylinder exhaust temperature is high F@BYNS(n361) (stage 1) No. 4,5,6 cylinder exhaust temperature is high F@BZNS(n371) (stage 1) Blow-by pressure is high F@BBZL(n338) No. 1,2,3 cylinder exhaust temperature is high F@BYNR(n362) (stage 2) No. 4,5,6 cylinder exhaust temperature is high F@BZNR(n372) (stage 2) Double meshing of transmission clutch Problem with lock-up clutch Problem with High clutch Problem with Low clutch 1500L0(b005) 1380MW(b021) 15H0MW(b022) 15J0MW(b023) 15K0MW(b024)
10 Problem with No. 1 clutch
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Table 3.2 Data items for manual snapshot

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Time Eng. speed Fuel inject Blow-by press. F. exh. temp. R. exh. temp. Eng. oil. press. Eng. oil. temp. Eng. cool. temp. Ambient temp. Boost press. Accelerator pos. Hoist lev. pos. T/C oil temp. T/M out. speed Shift indicator Lockup signal Retarder temp. F. brake press. R. brake press. Retarder position Foot brake position Item Elapsed time Engine speed Fuel injection amount Blow-by pressure Exhaust temperature (No. 1,2,3 cylinders) Exhaust temperature (No. 4,5,6 cylinders) Engine oil pressure Engine oil temperature Engine coolant temperature Ambient temperature Engine boost pressure Accelerator angle Hoist lever position Torque converter oil temperature Transmission output speed Gearshift range (position) Lock-up clutch Retarder oil temperature Front brake oil pressure Rear brake oil pressure Retarder brake use Foot brake use Content Unit sec. rpm mm3/st mmAq deg. C deg. C kg/cm2 deg. C deg. C deg. C mmHg % deg. C rpm ON-OFF deg. C kg/cm2 kg/cm2 ON-OFF ON-OFF Data collection point VHMS Engine controller Engine controller Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor Engine controller Oil temperature sensor Engine controller Engine controller (ambient temperature sensor) Engine controller Engine controller Retarder controller Transmission controller Transmission output shaft speed sensor Transmission controller Transmission controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller R = 10, N = 0, F1 = 1, F7= 7 FLOAT = 0, HOLD = 1, LOWER = 2, RAISE = 3, Max height = 4, Other = 5 Remarks
Table 4: Transmission trend data

No. 1 2 SMR Calendar Trig. time Low (fill time) Trig. time High (fill time) Trig. time Rev. (fill time) Trig. time 4th (fill time) Trig. time 3rd (fill time) Trig. time 1st (fill time) Trig. time 2nd (fill time) Item Service meter Calendar Content Unit h y/m/d h:m:s Data collection point Remarks
Transmission fill-up time
msec.
Transmission controller
(Every 200 h)
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5. Confirming data For details of the method of confirming the data, see the instruction manual for the technical analysis tool box. a Check that each file has been saved. Check also that there is no abnormal data. a Compare the quick PM data and the PM clinic data to check that there are no abnormal values. a After downloading, if there is no problem with the data, clear only the snapshot data. For details of the method of clearing, see the instruction manual for the technical analysis tool box (for service).
<Checking quick PM data> Engine speed (high idle, torque converter stall) Blow-by pressure (high idle, torque converter stall) Exhaust temperature (torque converter stall) Engine oil pressure (low idle, high idle, torque converter stall) Engine oil temperature (no PM data reference value)
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HD465-7, HD605-7
INSPECTION AND MAINTENANCE, REPLACING PARTS
INSPECTION AND MAINTENANCE

1. Inspection interval: Inspection and maintenance interval for machine Check the system at the same time as carrying out maintenance on the machine. 2. Inspection items a Carry out inspection and maintenance, and take the necessary action if there are any abnormalities. 1) Checks before starting (ask the customer also to carry out this inspection) i) Check that the sensors are installed properly. (Check that there are no loose, damaged, or dirty mounts) Blow-by sensor Engine oil temperature sensor Exhaust temperature sensor Ambient temperature sensor Communications antenna ii) Check that there are no disconnected or damaged wiring harnesses, cables, or connectors. iii) Check that there is no leakage of oil or gas from the sensor mounts. 2) Every 1000 hours service i) Communications antenna Check that there is no looseness at the antenna mount. Check that there is no damage or looseness of the antenna itself. If there is any abnormality, replace the antenna. 3) When required i) If there is any abnormality in the downloaded values, check all sensors. 3. Remedy If there is any abnormality, repair, replace, or reinstall (tighten).
REPLACING PARTS
If initial setup of VHMS system has been made or VHMS controller has been replaced If the system has been newly installed or the VHMS controller or other components (transmission, engine, etc.) have been replaced, it is necessary to carry out the initial setup of the system. Necessary tools 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) For details of the setup method, see the instruction manual for the technical analysis tool box (for service). The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. Or contact Komatsu. When replacing communications controller In the following cases, there are important procedures to be carried out, such as opening and closing of the communications controller, so follow the instruction of the person in charge at your company. Or contact Komatsu. 1) When replacing the controller installed on the machine with another controller. 2) When removing the controller installed on one machine and installing it on another machine. 3) When disposing of the controller. 4) When giving away or selling the machine with the controller installed. 5) When disposing of a machine with a controller installed.
HD465-7, HD605-7
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PROCEDURE FOR INITIAL SETUP OF VHMS

(Applicable machine models: HD465/605-7 Dump Truck)
Timing Operation step Operation step
* There are download connectors in two places (inside cabin, ground level download box), but the setting operation must be carried out inside the cab. 799-608-3220 Download cable Program for setting(VHMS technical analysis tool box) 799-608-3211 Portable PC
Check the serial No. first from the following nameplates and enter the serial No. on the check sheet. Machine Engine Transmission VHMS controller Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). Connect the other end to the RS232C port of the
portable PC.
Before starting operation
Prepare necessary parts, tools, and check sheet.
Contact Komatsu before starting the setup operation. (Contact at least 3 days before) 1. Check machine and component nameplates
Starting switch OFF
2. Connect PC and VHMS controller
Starting switch ON
3. Check that VHMS controller works properly

Do not start engine yet.
Check the 7-segment display window of the VHMS controller to see that the LED operation is normal. With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.
Start up the personal computer and click the VHMS initial setup tool icon.
4. Start VHMS initial setup tool (VHMS technical tool box)

(automatic updating of definition data)
For details of the method of installing the VHMS initial setup program, see the separate program operation instructions.
If the definition data for the connected machine is not in the technical analysis tool box on the personal computer, download automatically from the VHMS controller and update the technical analysis tool box. Press the YES button to update.
Icon
5. Initial setup of VHMS controller

After starting up, first input the ID (Service ID). Select "Data Clear and Set up".
Note: This program will not start if the VHMS controller and PC are not connected.
5-1 Setting up machine data

This sets the basic data for the machine in the VHMS controller.
The ID is the part No. for the VHMS controller. It differs according to the machine model.
1) Setting calendar Set the present time and date. 2) Confirming machine model and setting serial No. After checking the machine model, set the machine serial No. 3) Setting of variation code Select and set by clicking (See the attached table). 4) Setting engine Serial No. 5) Setting transmission Serial No. Set the transmission Serial No. in engine Serial No. 2. Finally, click OK. Click Apply to register the setting Check the 7-segment display in the VHMS controller inspection window. The display continues for several seconds after the starting switch is turned OFF. Check that the saving-to-memory display goes out completely.
Starting switch OFF
6. Saving of contents of setting

Turn the starting switch OFF to save the data in the VHMS controller. Starting switch ON
** When using the payload meter as shipped (default), the following setting is not necessary **
(Default setting) Time when collection is started: 12 o'clock (Midnight) Unit of collection (Day) : 1 day
Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller.
7. Setting of payload meter 7-1 Check of operation of VHMS controller
* The normal operation of the LED means that the 7 segments flash in the rotation state after the starting switch is turned to the ON position and then they count up in hexadecimal notation. For details, see the Shop Manual. Start the personal computer and click the icon of "VHMS initial setting tool".
For the method of installing the program for setting the VHMS initially,
7-2 Starting of VHMS initial setting tool

Icon
see the separate operation manual for the program.
If the definition information of the connected machine is not in "Analysis tool" of the personal computer, it is downloaded automatically from the VHMS controller and "Analysis tool" is updated.
Press the "yes" button to update. After the personal computer starts, input the ID (Service ID) first. Select "Set up".
(Cont'd)
(Cont'd)
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Timing
Operation step
7-3 Setting up payload meter
(Machine with PLM II or VHMS with PLM function (For details of setting up PLM, see the separate PLM instruction manual)
Operation step
Click the PLT tag to 1) Setting start time and interval (days) for
data collection
In the example on the right, the start time is set at 11 PM and the interval at 2 days.
Click Apply to register the setting
Starting switch OFF
8. Saving of contents of setting

Check the 7-segment display in the VHMS controller inspection window. The display continues for several seconds after the starting switch is turned OFF. Check that the saving-to-memory display goes out completely.
Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller. * The normal operation of the LED means that the 7 segments flash in the rotation state after the starting switch is turned to the ON position and then they count up in hexadecimal notation. For details, see the Shop Manual.
9. Check of normal operation of VHMS controller

Start engine
[Outline of procedure]
10. Execution of quick Pm clinic

Execute the quick Pm clinic according to the procedure shown in the Shop Manual.
1) Execute the quick PM while the engine is warm. 2) Select the service mode with the monitor panel, change the function, display "SNAPSHOT", and press the < > switch. Then, run the engine at Lo/Hi idle Be extremely careful about safety and stall the torque converter in 7 minutes 30 seconds. when carrying out the torque
Starting switch OFF
converter stall.
11. Saving in VHMS

Check lighting of the 7 segments in the inspection window of the VHMS controller.
The segments keep lighting for several seconds after the starting switch is turned off. (Saving operation) Check that the segments go off perfectly.
Check that the VHMS controller is connected to the portable personal computer by the cable.
12. Download
Start the "VHMS analysis tool" (VHMS technical analysis tool box) on the personal computer display. Download all files. For details, see the instruction manual for the technical analysis tool box.
13. Check of downloaded data
After downloading is finished, check the VHMS data with the "VIEW" function. Check that the set contents are displayed correctly. (Date, time, service meter, machine serial No., etc.) Check that the data of the quick Pm executed in [8] are saved in "Snap Shot".
14. Saving in VHMS

Turn the starting switch OFF to save the data in the VHMS controller. Starting switch OFF
1) After the starting switch is turned to the OFF position, the LED of the VHMS displays SF and SH (Processing time of memory), and then the all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.
After returning to office
Finish setting of the VHMS and notify to KOMATSU
This completes the initial setup of the VHMS. The setup of the database (Web server) is carried out by Komatsu, so after you have completed the operation, inform Komatsu as follows. [1] Send the check sheet by fax. [2] Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS/WebCARE Support Center

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD) Welcome to WebCARE
Use WebCARE to check the data https://wcare.komatsu.co.jp
TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu.co.jp
Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM controller
VHMS controller PLM function in VHMS controller Not installed Not installed Installed Card-type payload meter (PLM- ) Not installed Installed Not installed Installed Not installed Payload meter (PLM) function Set position of rotary switch 2 (SW2) of transmission controller F F B F 9 Setting with VHMS initial setting manual (tool) (*1) Model HD465 or HD605 Type 7 Set variation code ST P2 PV Set properly
Date Time Time difference (GMT) Summer time
Not installed Not installed Installed Installed Installed
Not installed Installed Not installed Installed Installed
a A variation code is an item among the model, date, etc. that are set with the personal computer software when the VHMS is set initially. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV), whether PLM is connected (Code: P2), and whether the machine has the payload meter (PLM) function (Code: ST)". a Since A and B of the short connector to be connected to connector No. HM-50 are not used, connect them normally. (*1) The transmission controller switch 2 (SW2) is used to notify the monitor panel "whether the VHMS is installed", "whether the PLM function in the VHMS is turned on", and "whether PLM- is installed". (See the section of adjustment of the transmission controller.)
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To: VHMS/WebCARE Support Center

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)
Date of setup Date of fax

Name of distributor/branch Name of person filling in check sheet
Month Month
Day Day
Year Year
FAX: 81-3-5561-4766
VHMS INITIAL SET-UP CHECK SHEET

(For HD465/605-7 Dump Truck)
Steps for setup 1. Check machine and component nameplates
Check items Name of machine Serial No. Service meter Engine serial No. Transmission serial No. VHMS controller serial No. Are they are properly connected? Does it work properly? (After rotation, hexadecimal count-up display) Is selection of mode for setup tool "Data Clear and Set up" ? Is model name same as name of machine? Has machine serial No. been input correctly? Was selection of variation code set correctly? Has engine serial No. been input correctly? Has date been set to today's date? Has time been set to correct time? After saving operation, did LED (7 segments) go off?
Results
2. 3.
Connect PC and VHMS controller Check that operation of VHMS controller is normal Start VHMS initial setup tool
yes yes
no no
4.
yes
yes yes yes yes yes yes yes
no
no no no no no no no
5.
Initial setup of VHMS controller

51 Set machine data This sets the basic data for the machine in the VHMS controller.
6. 7.
Save settings Setting of payload meter

71 Check of operation of VHMS controller 72 Starting of VHMS initial setting tool
Did LED operate normally? Is selection of mode of setting tool "Set up"? Enter set value of PLM collection Time to start collection Collection interval (day)
yes yes
no no
73 Setting of payload meter

(When PLM II or PLM function is installed)
day yes yes no no
8. 9.
Save settings Check of normal operation of VHMS controller
After saving operation, did LED (7 segments) go off? Did LED operate normally?
10. Perform quick PM clinic
Were service mode and "SNAPSHOT" selected and was switch pressed? After saving operation, did LED (7 segments) go off? Did LED operate normally? Have all files been downloaded? Time of download (use wrist watch) [Check data] Is there any MFAO error in Fault History? In Fault History, do set values for SMR and time match? Are there any data missing in Snapshot? Are there any data in Transmission Shift Change Map? After saving operation, did LED (7 segments) go off?
yes yes yes yes
no no no no
11. Save to VHMS memory 12. Download 13. Check downloaded data
yes yes yes yes yes
no no no no no
14. Save to VHMS memory
Point of Contact

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PROCEDURE FOR OPENING ORBCOMM SERVICE

(Applicable machine models: HD465/605-7 Dump Truck)
a Make a communications contract with Orbcomm before performing this work.
Timing Operation step Operation step
* There are download connectors at two places (inside cabin, ground level download box), but the setup operation must be carried out inside the cab. 799-608-3220 Download cable 799-608-3211 VHMS technical analysis tool box Portable PC
Check the serial No. first from the following nameplates and enter the serial No. on the check sheet. Machine Engine Transmission VHMS controller Orbcomm controller Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). Connect the other end to the RS232C port of the
portable PC.
Before starting operation
Prepare the necessary tools and check sheet. Contact Komatsu before starting the setup operation. (Contact at least 3 days before)
1. Check machine and component nameplates
Starting switch OFF
2. Connect PC and VHMS controller
Starting switch ON
Check the 7-segment display window of the VHMS controller to see that the LED operation is normal.
3. Check that VHMS controller works properly (Check that the Orbcomm controller works properly) (When an Orbcomm controller is installed)
* With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual. When checking that the operation of the Orbcomm controller is normal, wait for 3 minutes after starting the VHMS, then check the condition of the decimal point on the VHMS monitor (7-segment). OFF : ORBCOMM controller cannot communicate with ORBCOMM terminal. ON : Communication with ORBCOMM terminal is OK. Terminal does not have communication data. Quick flash : Communication with ORBCOMM terminal is OK. Terminal has communication data and has captured satellite. Slow flash : Communication with ORBCOMM terminal is OK. Terminal has communication data and has not captured satellite. Start up the personal computer and click the VHMS initial setup tool icon.
4. Start VHMS initial setup tool (VHMS technical tool box) (automatic updating of definition data)
Icon For details of the method of installing the VHMS initial setup program, see the separate program operation instructions.
If the definition data for the connected machine is not in the technical analysis tool box on the personal computer, download automatically from the VHMS controller and update the technical analysis tool box. Press the YES button to update.
After starting, input the ID (Service ID) first. Select "Set up".
5-1 Setting up communications (For machines with Orbcomm controller specifications)

This sets up the selection of VHMS
data to be sent by satellite communications
1) Selecting data to send There are 3 types of data that can be sent. With this operation is possible to set acceptance /refusal of satellite communications and the frequency of change. Decide the data to change, then click on * Edit to change it.
and the frequency of communications.
* (The setting of the machine data and PLM is already completed)
*1: The default for the number of items in the Fault History is 8. For details, see the instruction manual for the setup tool.
5-2 Set start of communications

2) Setting up GCC code Click Edit and select 130 (if Japan) for the GCC code. GCC code 1 120 121 122 123 130 Territory (country) USA ITALY MALAYSIA KOREA BRAZIL JAPAN
Finally, click Apply to register the setting.
(Cont'd)
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Timing
Starting switch OFF
Operation step
6. Save to VHMS memory
Turn the starting switch OFF to save the data in the VHMS controller.
Operation step
Check the 7-segment display in the VHMS controller inspection window. The display continues for several seconds after the starting switch is turned OFF. Check that the saving-to-memory display goes out completely.
1) After the starting switch is turned to the OFF position, the LED of the VHMS displays SF and SH (Processing time of memory), and then the all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.
After returning to office
Completing operation to set up VHMS and contacting Komatsu
This completes the setup for Orbcomm. The setup of the reception inside of the satellite communications is carried out by Komatsu, so after you have completed the operation, inform Komatsu as follows. 1) Send the check sheet by fax. 2) Send the downloaded VHMS data by Notes or E-mail to the following address.

(R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD) Welcome to WebCARE
Use WebCARE to check the data https://wcare.komatsu.co.jp
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HD465-7, HD605-7
To: VHMS/WebCARE Support Center

Date of setup Date of fax

Name of distributor/branch Name of person filling in check sheet
Month Month
Day Day
Year Year
FAX: 81-3-5561-4766
VHMS INITIAL SET-UP CHECK SHEET

(For HD465/605-7 Dump Truck)
Steps for setup 1. Check machine and component nameplates
Check items Name of machine Serial No. Service meter Engine serial No. Transmission serial No. VHMS controller serial No. Orbcomm controller serial No. Are they are properly connected?
Results
2. Connect PC and VHMS controller 3. Check that operation of VHMS controller is normal (Check operation of Orbcomm)
yes yes yes
no no no
Does it work properly? (After rotation, count-up display) Does VHMS monitor (7-segment) display decimal point? (OFF, ON, Slow/Quick flash)
Is selection of mode for setup tool "Data Clear and Set up"?
4. Start VHMS initial setup tool
yes
no

51 Set up communications * (The setting of the machine data and PLM is already completed)
52 Set start of communications
Input set value of short Fault History Condition of communications Number of items (default value: 8) Input set value of short Trend Analysis Condition of communications Interval (default value: 20 hrs) Input set value of short Payload data Condition of communications Time of start of data collection Data collection interval (day) Is GCC code set to 130 (if Japan)
On
items
Off
On
Hrs
Off
On
day
Off
yes
no
6. Save settings Point of Contact
After saving operation, did LED (7 segments) go off?
yes
no

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PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM)

What is quick Pm?
If a serious error occurs, the VHMS snapshot function saves all the data for a period of 5 minutes 30 seconds before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds). This snapshot function can be studied by pressing the manual switch. After the button is pressed, all data is automatically saved for seven minutes 30 seconds. All data can be automatically collected in cases such as torque converter stall, so it is possible to reduce the time taken for measurements in the Pm Clinic. However, the data sampling interval is one time every 10 seconds for the first 5 minutes and one time every 1 second for the next 2 minutes 30 seconds. To raise the precision of the data, it is necessary to create the conditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.
Necessary tools Personal computer VHMS technical analysis toolbox (software) 799-608-3211 Download cable 799-608-3220 To ensure safety, stop the machine on level ground and put chocks under the tires to prevent the machine from moving. 1. Start the engine. 2. Select SNAPSHOT with the monitor panel (EMMS). a For details of the method of selecting, see Special functions of vehicle monitor (EMMS).
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3. Press the [ ] button. "READY" is displayed. (Waiting status) 4. When the [ ] button is pressed, Snapshot is started and the time advances. (Running) If you want to stop, press the [ ] button to return to the Waiting status screen. 5. Run the engine at low idle and stabilize it for 2 minutes. a Check that the coolant temperature gauge and torque converter oil temperature gauge are in the white range. 6. After starting, operate the machine as shown in Table 1.
Table 1
Measurement conditions Start 1 2 3 4 5 6 7 8 9 0 : 00 2 : 00 3 : 00 4 : 00 5 : 00 5 : 30 6 : 00 6 : 30 7 : 00 Finish Time Operation of machine mode Shift lever AISS switch Power setting Auto Auto Auto Auto Auto Auto Auto Auto Auto Economy Economy Economy Economy Economy Economy Power Power Power N N N N N D N D N Parking brake ON OFF ON ON ON OFF ON OFF ON Retarder ON OFF ON ON ON ON ON ON ON Dump lever Hold Hold Float Hold Hold Hold Hold Hold Hold (*2, *3) (*2, *3) (*1) Remarks
2 : 00 120 sec Low idle (Low) 3 : 00 4 : 00 5 : 00 5 : 30 6 : 00 6 : 30 7 : 00 7 : 30 60 sec Low idle (Hi) 60 sec High idle (Stationary mode) 60 sec Low idle (Hi) 30 sec High idle (Economy mode) 30 sec Torque converter stall (Economy mode) 30 sec High idle (Power mode) 30 sec Torque converter stall (Power mode) High idle (Power mode) 30 sec + 20 pumping operations of foot brake
(*1) (*2)
(*3)
Press the foot brake. When stalling the torque converter [Portion marked with (*)], do not overheat it. [Stall of torque converter for 30 seconds is only a reference. When the oil temperature gauge reaches the top of the white range while the torque converter is stalled, return the transmission (gearshift) lever to the N position.] When setting the gearshift lever in the D position, return the engine speed to low idle temporarily (to prevent the machine from running out).
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7. After 7 minutes 30 seconds, the screen on the right is displayed for 5 seconds, and then it returns to the opening screen. (Completion of Snapshot)
8. Download the snapshot data to the personal computer. For details, see Procedure for downloading VHMS data to personal computer. NOTICE The quick PM data is only recorded once. If the operation is carried out again, the data is overwritten, so after performing the quick PM, always download the data to the personal computer. 9. Use the technical analysis tool box to read the quick PM data. a For details of the method of using the technical analysis tool box, see the instruction manual. Open the quick PM data and make a graph For the X-axis, select Time and for the Yaxis, select 1) Engine Speed 2) Blowby Press 3) Exhaust Temp 1, 2 & 3 4) Exhaust Temp 4, 5 & 6 5) Engine Oil Press and put a check mark against Graph value display at click position (marked by ).
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HD465-7, HD605-7
If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph.
(Example of graph display)
Enter these values on the Pm Clinic check sheet. The relationship between the measurement conditions and the necessary data in the Pm Clinic is as shown below.
Conditions Engine speed 1 2 3 4 5 6 7 8 Low idle Low idle High idle Low idle High idle Torque converter stall High idle Torque converter stall High idle + 20 pumping operations of foot brake Mode Low High Stationary mode Economy mode Economy mode Economy mode Power mode Power mode Engine speed Blow-by pressure Measurement items Lubricating oil Exhaust pressure temperature Brake oil pressure (*1)
Power mode
(*1) Cut OUT oil pressure and brake cut IN.
HD465-7, HD605-7
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PM-CLINIC SERVICE
HD465-7, HD605-7
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PM-CLINIC SERVICE
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PM-CLINIC SERVICE
HD465-7, HD605-7
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TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................... 20Sequence of events in troubleshooting ..................................................................................................... 20Points to remember when carrying out maintenance................................................................................ 20Checks before troubleshooting ................................................................................................................. 20Categories, procedure, and method of using troubleshooting charts........................................................ 20Connection table for connector pin numbers ............................................................................................ 20T-adapter table .......................................................................................................................................... 20Types and locations of connectors ........................................................................................................... 20Connector arrangement location............................................................................................................... 20302 303 304 312 313 318 341 344 356
Troubleshooting of engine controller system (ENG mode) ....................................................................... 20- 401 Troubleshooting for transmission controller system (TM mode) ............................................................... 20- 501 Troubleshooting for retarder controller system (BK mode) ....................................................................... 20- 701 Troubleshooting for payload meter system (card type) (LC mode) ........................................................... 20- 801 Troubleshooting for monitor system (MON mode) .................................................................................... 20- 901 Troubleshooting of VHMS controller system (VHMS mode) ..................................................................... 20-1001 Troubleshooting of ASR controller system (ASR mode) ........................................................................... 20-1051 Troubleshooting of hydraulic and mechanical systems (H mode) .............................................................20-1101 Troubleshooting of engine system (S mode) ............................................................................................20-1151 Troubleshooting of electrical system (E mode) ........................................................................................ 20-1201 Troubleshooting of ABS controller system (ABS mode) (If equipped) ...................................................... 20-1251
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TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level ground, and check that the safety pin, chocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: Parts that have no connection with the failure or other unnecessary parts will be disassembled. It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the ma chine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. 2) Check the CHECKS BEFORE STARTING items. Other inspection items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. W hen operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that ma y make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause. 3) 4)
4.
5.
2.
6.
3.
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TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING

TEW00180 TEW00181
Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. Name of customer Type, serial number of machine Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. 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 tools. T-adapter Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.
TEW00186
Step 7 Pinpoint locations of failure (carry out troubleshooting) Decide action to take 1) Before starting troubleshooting, locate and 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 Go to jobsite
Step 5 Ask operator questions to confirm details of failure.

TEW00189
Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure?
HD465-7, HD605-7
20-303
(2)
TROUBLESHOOTING
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 equipment 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 protecting 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 damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-304
(10)
HD465-7, HD605-7
TROUBLESHOOTING
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 broken.
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 appropriate action before passing electricity through it.
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
HD465-7, HD605-7
20-305
(10)
TROUBLESHOOTING
2) Removing, installing, and drying connectors and wiring harnesses i) Disconnecting connectors a) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. b) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. a If the connector is twisted up and down or to the left or right, the housing may break.
c) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-306
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ii) Connecting connectors a) Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. b) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. c) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. d) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
HD465-7, HD605-7
20-307
(10)
TROUBLESHOOTING
iii) Connecting DT connectors Since the DT 8-pole and 12-pole heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. Male connector (1). Female conector (2). Normal locking state (Horizontal): a, b, d Incomplete locking state (Diagonal): c
iv) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. a) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
b) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
c) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with contact restorer and reassemble.
20-308
(10)
HD465-7, HD605-7
TROUBLESHOOTING
3) Handling control box i) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. ii) Do not open the cover of the control box unless necessary.
iii) Do not place objects on top of the control box. iv) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. v) During rainy weather, do not leave the control box in a place where it is exposed to rain.
vi) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). vii) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
HD465-7, HD605-7
20-309
(10)
TROUBLESHOOTING
3. POINTS TO REMEMBER HYDRAULIC EQUIPMENT
WHEN
HANDLING
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm 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 openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out 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 refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil 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
(1)
HD465-7, HD605-7
TROUBLESHOOTING
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
HD465-7, HD605-7
20-311
(1)
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

(1. Check before starting and 2. Other check items)
Item 1. Check fuel level
Hydraulic oil, lubricating oil,coolant
Judgement value Fuel level Sight gauge Sight gauge Oil level gauge Dust indicator Max. 135 mm Actuation 20 sec Label
Torque (see DISASSEMBLY AND ASSEMBLY)
Action Add fuel Drain Add oil Add oil Add oil Add coolant Clean, replace Adjust Repair Repair Inflate or replace Tighten Adjust Adjust or repair Adjust or repair Adjust or repair Adjust Adjust or repair Adjust or repair Replace Repair Repair or replace Adjust or repair Adjust or repair Repair or replace Adjust or repair Retighten or clean Retighten or clean Retighten or clean
2. Water, sediment in fuel tank 3. Check oil level in transmission case 4. Check oil level in hydraulic tank 5. Check oil level in engine oil pan 6. Check coolant level 7. Check dust indicator 8. Check that steering wheel play is correct 9. Check emergency steering
Air, hydraulic, mechanical components
10. Check length of suspension cylinder 11. Check tire inflation pressure, check for damage 12. Check hub nuts 13. Check foot brake effect 14. Check parking brake effect 15. Check that emergency brake works properly 16. Check that there is no abnormality in operation of steering 17. Check that direction of rear view mirror and under mirror is correct
18. Check that there is no abnormality in exhaust color or sound
Check before starting items
19. Check that retarder brake works properly 20. Check that body mount rubber is normal 21. Check that horn sounds 22. Check that lamps flash properly Electrical components 23. Check that gauges work properly during operation 24. Check monitor panel 25. Check mechanical monitor system 26. Check central warning lamp 27. Check for looseness, corrosion of battery terminal wiring 28. Check for looseness, corrosion of alternator terminal wiring 29. Check for looseness, corrosion of starting motor terminal wiring
20-312
(10)
HD465-7, HD605-7
Item
Hydraulic, mechanical equipment
Judgement value 24V 27.5 29.5 V Repair Repair
Action
30. Check for abnormal noise or smell 31. Check for oil leakage 32. Air bleed operation 33. Check battery voltage (engine stopped)
Bleed air Charge or replace Add distilled water Replace Repair Dry Replace Replace Replace
Other check items
Electrics, electrical components
34. Check battery electrolyte level 35. Check wiring for discoloration, burn marks, peeling of cover 36. Check for loose wiring clamps, hanging wiring 37. Check for wet wiring (be particularly careful to check connectors and terminals) 38. Check for blown fuses, defective contact 39. Check alternator voltage after several minutes of running (engine at 1/2 throttle or above) 40. Check for actuation sound from battery relay (when starting switch is turned ON-OFF)
HD465-7, HD605-7
20-312-1
(10)
TROUBLESHOOTING
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code a If the machine monitor displays a failure code, it also displays the controller name at the same time, so the troubleshooting codes are categorized to match each controller name. (This may also include the electrical system, where some failure codes are not displayed). a The hydraulic and mechanical system, for which the machine monitor cannot display a failure code, is categorized as H Mode.
Troubleshooting Code ENG TM BK LC MON HM H S E Troubleshooting System Troubleshooting of engine controller system Troubleshooting for transmission controller system Troubleshooting for retarder controller system Troubleshooting for payload meter system (card type) Troubleshooting for monitor system Troubleshooting VHMS controller system Troubleshooting of hydraulic and mechanical systems Troubleshooting of engine body Troubleshooting of electrical system
2. Troubleshooting procedure a If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows. 1) When machine monitor displays failure code If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the content of the display, then go to the applicable troubleshooting chart for the failure code. 2) When machine monitor does not display failure code, but fault history is recorded If a problem occurs but the failure code display cannot be checked on the machine monitor, use the fault history display function in the machine monitor service mode to check for a failure code. If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable troubleshooting chart. 3) When machine monitor does not display failure code and fault history is also not recorded If a problem occurs but the failure code display cannot be checked on the machine monitor, and the problem is also not recorded by the fault history display function in the machine monitor service mode, there is a probability that is a problem in the electrical system that cannot be detected by a controller or that a problem has occurred in the hydraulic and mechanical system. In this case, check the nature of the problem and go to the applicable troubleshooting chart.
HD465-7, HD605-7
20-313
(11)
TROUBLESHOOTING
Phenomena considered to be failures and troubleshooting No. q go to troubleshooting No. on failure code display
Troubleshooting No. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode S mode
Error code related 1 Error code is displayed in error code display mode
q
ENG-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 ENG-2a) ENG-2b) ENG-3a) ENG-3b) TM1 27
Engine related 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Engine does not start Starting performance is poor (starting always takes time) Engine does not turn Engine turns but no exhaust smoke comes out Exhaust smoke comes out but engine does not start
Engine does not pick up smoothly (follow-up is poor) Engine stops during operations Engine does not rotate smoothly (hunting) Engine lacks output (or lacks power) Exhaust smoke is black (incomplete combustion) Oil consumption is excessive (or exhaust smoke is blue) Oil becomes contaminated quickly Fuel consumption is excessive Oil is in coolant, or water spurts back, or coolant level goes down Oil pressure caution lamp lights up (drop in oil pressure) Oil level rises Coolant temperature becomes too high (overheating) Abnormal noise is made Vibration is excessive Failure in preheating AISS function does not work normally Engine is not preheated Engine is still preheated after preheating time When AISS switch is set in AUTO, LOW SPEED control is selected When AISS switch is set in LOW SPEED, AUTO control is selected
21 22
Not error code is displayed in error code display mode
Transmission controller related 23 24 25 26 27 Fuel level gauge does not operate normally (It always indicates "FULL") When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON Abnormality in Backup lamp is not turned ON backup lamp (Backup buzzer is normal) and backup Backup buzzer is not turned ON buzzer (Backup lamp is normal) While shift lever is not operated, backup lamp and backup buzzer TM-1 TM-2a) TM-2b) TM-2c) TM-2d)
20-314
(10)
HD465-7, HD605-7
TROUBLESHOOTING
Retarder controller related When the parking brake switch is set in the OFF position, the parking brake s not released When the parking brake switch is set in the PARK position, the parking brake does not work Retarder brake oil temperature gauge does not operate normally Inclination alarm is turned ON when dump body is raised (When chassis is not inclined laterally more than 15) Parking brake does not operate normally Touch up/down and cancellation cannot be performed BK-1a) BK-1b) BK-2 BK-3 BK-4
28
29 30 31
Payload meter related 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 When starting switch is turned ON, any item is not displayed After starting switch is turned ON, all external pilot lamps do not light up External lamps light up while condition for lighting is not set Lighting level of external pilot lamps is abnormal Cycle data and engine ON/OFF data not recorded (charge level signal system: judges that engine is stopped) Calibration cannot be performed and displayed clock does not conform to condition (shift lever "N" position signal system) When loaded dump truck starts traveling, "0" is kept displayed After loaded dump truck start traveling, display of odometer does not increase Displayed logic When travel speed exceeds limit is abnormal speed, "SP:SP" does not go off Integrated pay load is not displayed Displayed and saved pay load is not correct Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in "FLOAT" position while truck is not dumping) Payload meter displays "F:09" (lowering of internal backup battery voltage) Payload meter displays " :FULL" (data saving memory is full) Payload meter displays "F-20" :failure in power source of suspension pressure sensor and clinometer system Payload meter displays "F-21" "F-24" : disconnection or grounding fault in suspension pressure sensor signal system Payload meter displays "F-25" "F-28" : short circuit with power source in suspension sensor signal system Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) Payload meter displays "F:43" "F:45" (short circuit with power source in external pilot lamp relay system) Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) 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 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal system Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal system Payload meter displays "F:18" (disconnection in charge level signal system) LC-1 LC-2 LC-3 LC-4 LC-5 LC-6 LC-7a) LC-7b) LC-7c) LC-7d) LC-7e) LC-8 LC-9 LC-10 LC-11 LC-12 LC-13 LC-14 LC-15 LC-16 LC-17 LC-18 LC-19 LC-20
HD465-7, HD605-7
20-315
(10)
TROUBLESHOOTING
Monitor related 56 57 When starting switch is turned ON, machine monitor does not display any item When starting switch is turned OFF and machine monitor does not operate normally Alarm buzzer defective Items displayed by gauges, caution lamps, and character display of machine monitor are abnormal Alarm buzzer does not sound Alarm buzzer does not stop sounding Items displayed by gauges are different from machine condition Items displayed by caution lamps are different from machine condition Character display does not display any item or it displays abnormally MON-1 MON-2 MON-3a) MON-3b) MON-4 MON-4 MON-4 MON-5 MON-6 MON-6 MON-7 MON-8a) MON-8b) MON-9a)
58
59
60
Operation of machine monitor cannot be checked normally Display of character display cannot be selected normally Machine monitor mode select switch 1 system is abnormal Machine monitor mode select switch 2 system is abnormal
61
62
Power mode select function does not work normally Seat belt caution lamp does not operate normally Lamp lights up while seat belt is fastened Lamp does not light up while seat belt is unfastened When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash When turn signal lever and hazard lamp switch are operated, the turn 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 lamp switch is operated, however, turn signal lamps flash normally) W h e n h a z a r d l a m p s w it c h i s turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally) W h e n h a z a r d l a m p s w it c h i s turned OFF, turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally) Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up When lamp switch is set in 1st position, small lamp and night lamp do not light up When lamp switch is OFF, small lamp and night lamp light up When dimmer switch is operated, brightness of night lighting does not change Head lamp "Hi" beam does not light up
63
MON-9b)
MON-9c)
64
Turn signals and hazard lamp do not operate normally
MON-9d)
MON-9e)
MON-9f)
MON-10a)
MON-10b) MON-10c) MON-10d) MON-10e)
65
Night lighting is abnormal
20-316
(10)
HD465-7, HD605-7
TROUBLESHOOTING
Troubleshooting No. Phenomena considered to be failures Head lamp "Lo" beam does not light up Head lamp cannot be set to "Hi" or "Lo" When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up Left window does not work Right window does not work Air conditioner does not operate Air is not blown out or airflow cannot be adjusted Air is not cooled or temperature cannot be adjusted (Electric system) Defective air conditioner Inside air and fresh air cannot be selected Air outlet cannot be selected Cooling capacity is low (Mechanical system) Heating capacity is low (Defective hot water circuit) Abnormal noise comes out Water leaks VHMS Abnormality in satellite data communication Satellite communication data are not transmitted Downloading into PC VHMS-2 VHMS-3 Error code ENG mode TM mode BK mode LC mode MON mode MON-10f) MON-10g) MON-10h) MON11a) MON11b) MON12a) MON12b) MON12c) MON12d) MON12e) MON12f) MON12g) MON12h) MON12i) VHMS mode H mode S mode
65
Night lighting is abnormal
66
Power window does not operate normally
67
68
VHMS-1
69 70
Abnormality in saving in VHMS controller (Data are not saved) Engine blow-by pressure of monitoring display is low (when measurement equipment shows blow-by pressure is normal)
Hydraulic and mechanical related 71 72 73 74 75 Machine does not start Machine does not travel smoothly Lock-up clutch cannot be disengaged Excessive shock when starting or shifting Transmission does not shift up Abnormality at all speed ranges 76 Machine lacks power or speed when traveling Torque converter lock-up does not engage Abnormality at specific speed ranges H-1 H-2 H-3 H-4 H-5 H-6a) H-6b) H-6c) H-7 H-8 H-9 H-10 H-11
77 78 79 80 81
Time lag is excessive when starting or shifting gear Torque converter oil temperature is high Torque converter oil pressure is low Front brake is ineffective, or effective only on one side Rear brake is ineffective, or effective only on one side
HD465-7, HD605-7
20-317
(10)
TROUBLESHOOTING
Troubleshooting No. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode H-12 H-13 H-14 H-15 H-16 H-17 S mode
82 83 84 85 86 87
Steering wheel is heavy Steering wheel does not work Steering wheel vibrates Hoist cylinder lacks lifting force (lifting speed) Hoist cylinder does not work Excessive hydraulic drift of dump body
20-317-1
(9)
HD465-7, HD605-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the mating portion of the housing. No. of pins 1 X-type connector Male (female housing) Part No.: 08055-00181 Female (male housing) Part no.: 08055-00191 T-adapter Part No. 799-601-7010
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
799-601-7040
Part No.: 08055-00481

Terminal part no.: 79A-222-3370 Electric wire size: 0.85 Grommet: black Quantity: 20 Terminal part no.: 79A-222-3380 Electric wire size: 2.0 Grommet: red Quantity: 20
Part No.: 08055-00491

Terminal part no.: 79A-222-3390 Electric wire size: 0.85 Grommet: black Quantity: 20 Terminal part no.: 79A-222-3410 Electric wire size: 2.0 Grommet: red Quantity: 20
20-318
(10)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
SWP-type connector Male (female housing) Female (male housing) T-adapter Part No.
799-601-7050
Part No.: 08055- 10681
Part No.: Part No.: 08055- 10691
799-601-7060
Part No.: 08055-10881
Part No.: 08055- 10891
12
799-601-7310
Part No.: 08055- 11281
Part No.: 08055- 11291
14
799-601-7070
Part No.: 08055- 11481
Part No.: 08055-11491
HD465-7, HD605-7
20-319
(1)
TROUBLESHOOTING
No. of pins
SWP-type connector Male (female housing) Female (male housing) T-adapter Part No.
16
799-601-7320
Part No.: 08055-11681

Terminal part no.: Electric wire size: 0.85 Grommet: black Quantity: 20 Terminal part no.: Electric wire size: 1.25 Grommet: red Quantity: 20
Part No.: 08055-11691

Terminal part no.: Electric wire size: 0.85 Grommet: black Quantity: 20 Terminal part no.: Electric wire size: 1.25 Grommet: red Quantity: 20
20-320
(10)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins 1
M-type connector Male (female housing) Part No.: 08056-00171 Female (male housing) Part No.: 08056-00181 T-adapter Part No. 799-601-7080
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
799-601-7340
Part No.: 08056-00871
Part No.: 08056-00881
HD465-7, HD605-7
20-321
(7)
TROUBLESHOOTING
No. of pins
S-type connector Male (female housing) Female (male housing) T-adapter Part No.
799-601-7140
Part No.: 08056-10871
Part No.: 08056-10881
10 (white)
799-601-7150
Part No.: 08056-11071
Part No.: 08056-11081
12 (white)
799-601-7350
Part No.: 08056-11271
Part No.: 08056-11281
16 (white)
799-601-7330
Part No.: 08056-11671
Part No.: 08056-11681
20-322
(10)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
S-type connector Male (female housing) Female (male housing) T-adapter Part No.
10 (blue)
12 (blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16 (blue)
799-601-7170
Part No.: 08056-11672
Part No.: 08056-11682
HD465-7, HD605-7
20-323
(1)
TROUBLESHOOTING
No. of pins 7 11
MIC type connector Male (female housing) Housing part No.: 79A-222-2640 Qty.: 5 Housing part No.: 79A-222-2680 Qty.: 5 Female (male housing) Housing part No.: 79A-222-2630 Qty.: 5 Housing part No.: 79A-222-2670 Qty.: 5 T-adapter Part No.
799-601-2710
Housing part No.: 79A-222-2620 Qty.: 5
799-601-2950
13
799-601-2720
20-324
(10)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
MIC type connector Male (female housing) Female (male housing) T-adapter Part No.
17
799-601-2730
21
799-601-2740
Housing part No.: 79A-222-2750 Qty.: 2 Housing part No.: 79A-222-2770 Qty.: 50
Housing part No.: 79A-222-2740 Qty.: 2 Housing part No.: 79A-222-2760 Qty.: 50
HD465-7, HD605-7
20-325
(1)
TROUBLESHOOTING
No. of pins
AMP040-type connector Male (female housing) Female (male housing) T-adapter Part No.
799-601-7180
12
799-601-7190
16
799-601-7210
20
799-601-7220
aTerminal part No.: 79A-222-3470 (no relation with number of pins)
20-326
(1)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
AMP070-type connector Male (female housing) Female (male housing) T-adapter Part No.
10
799-601-7510
Part No.: 7821-92-7330
12
799-601-7520
Part No.: 7821-92-7340
14
799-601-7530
Part No.: 7821-92-7350
18
799-601-7540
Part No.: 7821-92-7360
20
799-601-7550
Part No.: 7821-92-7370
HD465-7, HD605-7
20-327
(9)
TROUBLESHOOTING
No. of pins
L type connector Male (female housing) Female (male housing) T-adapter Part No.
No. of pins
PA type connector Male (female housing) Female (male housing) T-adapter Part No.
No. of pins
Bendix MS connector Male (female housing) Female (male housing) T-adapter Part No.
10
799-601-3460
20-328
(10)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.
Part No.: 08027-10210 (natural color) 08027-10220 (black)
Part No.: 08027-10310
Part No.: 08027-10360
HD465-7, HD605-7
20-329
(1)
TROUBLESHOOTING
No. of pins
KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.
20-330
(1)
HD465-7, HD605-7
TROUBLESHOOTING
No. of pins
Connector for relay (socket type) Male (female housing) Female (male housing) T-adapter Part No.
799-601-7360
799-601-7370
HD465-7, HD605-7
20-331
(10)
TROUBLESHOOTING
No. of pins
F-type connector Male (female housing) Female (male housing) T-adapter Part No.
20-332
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)]
Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No.
18-8 (1)
Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male terminal)
799-601-9210
18-14 (2)
Part No.: 08191-24101, 08191-24102 08191-24105, 08191-24106 Pin (male terminal) 799-601-9220
Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206
Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106
HD465-7, HD605-7
20-333
(10)
TROUBLESHOOTING
18-20 (3)
Part No.: 08191-31201, 08191-31202 Pin (female terminal)
Part No.: 08191-34101, 08191-34102 799-601-9230 Pin (male terminal)
Part No.: 08191-32201, 08191-32202 Pin (male terminal)
18-21 (4)
Part No.: 08191-42201, 08191-42202
Part No.: 08191-43101, 08191-43102
20-334
(10)
HD465-7, HD605-7
TROUBLESHOOTING
24-9 (5)
Part No.: 08191-52201, 08191-52202 Pin (male terminal)
24-16 (6)
Part No.: 08191-61201, 08191-62202 08191-61205, 08191-62206 Pin (female terminal)
Part No.: 08191-64101, 08191-64102 08191-64105, 08191-64106 799-601-9260 Pin (male terminal)
Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206
Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106
HD465-7, HD605-7
20-335
(10)
TROUBLESHOOTING
24-21 (7)
Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 799-601-9270 Pin (male terminal)
24-22 (8)
Part No.: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-81206 Pin (female terminal)
Part No.: 08191-84101, 08191-84102, 08191-84103, 08191-84104, 08191-84105, 08191-84106 799-601-9280 Pin (male terminal)
Part No.: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206
Part No.: 08191-83101, 08191-83102, 08191-83103, 08191-83104, 08191-83105, 08191-83106
20-336
(10)
HD465-7, HD605-7
TROUBLESHOOTING
24-31 (9)
Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 799-601-9290 Pin (male terminal)
Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206
Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106
HD465-7, HD605-7
20-337
(10)
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)] DT series connector Body (plug) Body (receptacle) T-adapter Part No.
No. of pins
799-601-9020
Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)
799-601-9030
799-601-9040
799-601-9050
20-338
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)] DT series connector Body (plug) Body (receptacle) T-adapter Part No.
No. of pins
8Gr: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8Br: 799-601-9090
Part No.: 08192-1820 08192-2820
(normal type) (fine wire type)
12
12Gr: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12Br: 799-601-9140
HD465-7, HD605-7
20-339
(10)
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)] DTM series connector Body (plug) Body (receptacle) T-adapter Part No.
No. of pins
799-601-9010
Part No.: 08192-02200
Part No.: 08192-02100
[The pin No. is also marked on the connector (electric wire insertion end)] DTHD series connector Body (plug) Body (receptacle) T-adapter Part No.
No. of pins
Part No.: 08192 - 31200 (contact size #12) 08192 - 41200 (contact size #8) 08192 - 51200 (contact size #4)
Part No.: 08192 - 31100 (contact size #12) 08192 - 41100 (contact size #8) 08192 - 51100 (contact size #4)
20-340
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins DRC26 Series connector Body (plug) Body (receptacle) T-adapter Part No.
24
799-601-9360
Part No.: 7821-93-3110
40 (A)
799-601-9350
Part No.: 7821-93-3120
40 (B)
799-601-9350
Part No.: 7821-93-3130
HD465-7, HD605-7
20-340-1
(9)
TROUBLESHOOTING
T-ADAPTER TABLE
T-ADAPTER TABLE
KIT No. 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300
Port No.
Connector type
Pin No.
799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070
For measuring box For measuring box For measuring box For measuring box Plate Plate Plate BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) CASE MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Extension cable CASE X X X X SWP SWP SWP SWP
Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P
Q Q Q Q Q
Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q Q Q Q Q
Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q
1P 2P 3P 4P 6P 8P 12P 14P
Q Q Q Q Q
Q Q Q Q Q
HD465-7, HD605-7
20-341
(12)
TROUBLESHOOTING
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
799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220
SWP M M M M M M S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30
16P 1P 2P 3P 4P 6P 8P 8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2
Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
10P 12P 14P 18P 20P 5p 6p 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Blown 12P-Gray 12P-Black 12P-Green 12P-Blown 18-8 18-14
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q
20-342
(12)
HD465-7, HD605-7
Port No.
Connector type
Pin No.
Q Q Q
TROUBLESHOOTING
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
799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410 799-601-9420 799-601-9430
HD30 HD30 HD30 HD30 HD30 HD30 HD30 Plate For measuring box Case Case DRC26 DRC26 For NE, G sensor For boost pressure, fuel PVC socket
18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q
40P 24P 2P 3P 2P
Q Q Q Q Q
HD465-7, HD605-7
20-343
(12)
Port No.
Connector type
Pin No.
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS

ConType Numnector of ber No. connector of pin 01 02 03 04 05 06 07 08 11 12 12 13 14 15 16 17 18 20 21 22 23 1939 A A A1 A2 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal KES0 Terminal Terminal Terminal Terminal Terminal Terminal HD30
One-pin connector One-pin connector
Address Location
3-dimensional wiring diagram ENG
System diagram TM K-8 K-8 K-8 K-8 K-9 K-9 K-9 K-9 BK H-9 H-8 H-8 H-8 PLM K-9 K-8 K-8 K-8 MON VHMS N-9 N-8 N-8 N-8 ASR
1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 9 1 1 1 1 3 6 1 2 3 3 5 5
Battery relay (B) Battery relay (M) Battery relay (B) Battery relay (M) Emergency steering relay (B) Emergency steering relay (M) Emergency steering relay (B) Emergency steering relay (M) Battery relay (E) Battery relay (BR) Washer tank motor Battery relay (E) Battery relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Circuit breaker Circuit breaker Circuit breaker Circuit breaker
Connector for connecting J1939 device
B9 B9 B9 B9 A8 A8 A8 A9 B8 B8 C8 C8 A8 A7 B7 B7 A9 A9 A9 B9 X6 V8 AH5 O2 M3 T2 L4 K3 V3 M6
J-1 J-1 J-1 J-1
J-1 J-1 J-1 J-1
K-8 K-8 K-8 K-8
H-9 H-8
K-9 K-8
N-9 N-8
H-8 H-8
K-8 K-8
N-8 N-8
K-9 K-9 K-9 K-8 L-8 L-8 J-2 I-2 G-9 J-9 H-1 B-7 B-7 B-1 E-9 C-7 A-9 L-2 L-2 K-4 K-4 A-8 B-9 K-8 K-8 I-8 I-8 L-8 L-8 N-8 N-7 N-8 N-7 A-3
Lamp (Optional for payload meter) Lamp (Optional for payload meter) Emergency reset connector Emergency reset connector Air pressure sensor ABS system switch Air conditioner wiring harness Air conditioner blower motor ACC oil pressure sensor (Front) ACC oil pressure sensor (Rear) Temperature regulation servomotor
Air outlet mode selection servomotor
M M
AAPR PACKARD ABS AC1 ACBM ACCF ACCR ACM1 ACM2 M

One-pin connector
YAZAKI DT-T DT-T AMP AMP
20-344
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin ACM3 ACP1 ACP2 AMP AMP AMP 5 16 12 2 4 4 4 4 4 4 2 6 3 6 6 3 6 2 2 2 2 2 2 2 2 17 21 20 16 12 20 16 4 6 6
Address Location
System diagram TM BK PLM MON VHMS A-7 B-9 B-9 A-8 A-8 A-8 A-7 A-7 A-7 A-8 A-8 ASR
Recirculated/Fresh air selection servomotor
W3 O7 O7 U2 W3 W4 W4 W4 W4 U2 U3 M3 P8 N3 N2 O2 O2 C2 L2 K3 L3 K3 L2 K1 T2 Z1 Z1 Z4 Z4 AA4 AA1 AA4 W4 K9 K8 L-7 L-7 L-8 L-8 A-7 A-7 A-6 A-6 A-5 A-5 A-4 A-3 E-1 E-1 E-1 F-1 E-1 E-1 E-1 L-2 C-8 L-5 F-9 C-1
Air conditioner control panel Air conditioner control panel Air conditioner pressure switch Blower main relay Blower Hi relay Blower M2 relay Blower M1 relay Compressor clutch relay Air conditioner blower resistor Thermistor AISS switch ARSC set switch ARSC system switch Acceleration sensor Acceleration sensor ASR system switch Steering angle sensor Shut off valve ASR valve (R) ASR valve (L) ASR oil pressure switch (R) ASR oil pressure switch (L) ASR oil ptessure switch (Main) Air suspension seat Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller
Software rewriting connector (Transmission controller)
ACPS SUMITOMO ACR1 ACR2 ACR3 ACR4 ACR5 ACRE ACTH AISS ARC ARSC AS1 AS2 ASR ASR1 ASR2 ASR3 ASR4 ASR5 ASR6 ASR7 ASS ATC1 ATC2 Relay Relay Relay Relay Relay AMP YAZAKI M M M SWP X M DT-T-T DT-T-T DT-T-T DT-T-T DT-T DT-T DT-T DT-T MIC MIC
F-9
F-9
F-5 C-9 D-9 D-9 E-9 E-9 F-9 F-9
H-1
ATC3A AMP040 ATC3B AMP040 ATC4 AMP040
I-1
ATC5A AMP040 ATC5B AMP040 ATC6 B01 B02 X DT-T DT-T
Intermediate connector Intermediate connector
M-5 M-5
HD465-7, HD605-7
20-345
(5)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin B03 B04 B05 B06 B07 B1 B1 B10 B11 B2 B2 B3 B3 BCOM BK BL BLS BR BRC1 BRC2 DT-T Terminal Terminal Terminal DT-T
Address Location
System diagram TM BK PLM MON VHMS M-6 F-9 F-9 F-9 K-5 I-9 H-1 G-9 M-4 M-5 J-9 H-1 J-9 H-1 A-2 H-2 I-8 C-9 C-7 M-2 M-6 M-6 M-6 ASR
6 1 1 1 3 1 1 1 1 1 1 1 1 1 8 1 6 1 17 21 20 16 12 20 16 4 6 2 8 8 3
Winker lamp, stop lamp, tail lamp Backup lamp Backup alarm buzzer Backup alarm buzzer Body position sensor
Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped)
J9 J9 J9 J9 K9 K8 L8 T9 F9 C7 N1 M4 Y2 Y2 Y4 Y4 Z4 Y1 Y2 S9 C9 X5 X7 X6 X6 R1 Q9 Q9 AJ6 H-9 B-9 L-6 L-4 L-4 L-3 I-2 H-6 E-3 E-2 E-2 E-2 F-3 F-3 C-1 J-9 C-1 C-1 J-9 C-1 A-8 A-7 A-6 A-5 A-5 A-4 A-3 A-2 G-8 J-6 E-7 E-7 E-6 E-6 D-1 D-1 D-1
Terminal Terminal
One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector DT-T (Gray) One-pin connector
Grounding Grounding
Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped)
Beacon lamp Intermediate connector Intermediate connector Rotary lamp switch (If equipped) Air conditioner wiring harness Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller
Software rewriting connector (Retarder controller)
M
One-pin connector
MIC MIC
H-1 A-1 B-1
BRC3A AMP040 BRC3B AMP040 BRC4 AMP040
H-1
BRC5A AMP040 BRC5B AMP040 BRC6 BT BT1 BT2 BT3 BT4 BZ2 CAB1 CAB2 CAN X DT M
DT-T (Gray) DT-T (Black)
D-1
Intermediate connector Fuse box Fuse box Fuse box Fuse box Buzzer Intermediate connector Intermediate connector CAN connector
M-9 K-3 I-3 K-3 I-3 D-9 F-1 F-4
DT
M-3
A-2
20-346
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin CAN1 CAN2 CG1 CG2 CH1 CH2 CJA CJB CJB CJC CJD CJE2 CJE3 CJH1 CJH2 CJK CJL CJN CJP CJP1 CJP2 CJPR CJS CJSL CJT CJT1 CJT2 CJW CK1 DT-T DT-T
One-pin connector
Address Location
System diagram TM BK PLM MON VHMS C-9 F-9 D-9 ASR
3 3 1 1 8 8 6 8 6 6 6 6 8 8 6 6 6 8 6 6 6 6 6 6 8 8 6 6 6 2 8 2 2 2 2
VHMS CAN connector Resistor Cigarette lighter Cigarette lighter

Machine monitor mode selector switch 1 Machine monitor mode selector switch 2
T9 Q1 M5 M5 M1 M1 D8 B7 E8 D8 D8 AI9 A12 B8 L7 J3 I9 H9 I9 C8 L7 I9 L8 L7 H9 G-9 G-1 G-1 I-1 I-1 J-9 H-9 G-1 G-1 H-9 M-1 M-1 I-9 L-3 J-1 J-1 H-9 I-1 I-1 I-1 J-1 I-1 H-1 I-9 J-1 J-9 K-1 G-8 H-9 H-9 I-1
S S DT-T
DT-T (Black)
E-9 E-9 L-9 M-9 L-9
Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Bulb breakage check switch Coolant temperature sensor
Lighting switch, passing switch, turn switch
DT-T DT-T DT DT-T

DT-T (Black) DT-T (Black)
M-9
N-7 M-1
DT-T DT DT-T DT (Black) DT-T DT-T DT-T DT-T DT-T DT-T

DT (Black) DT-T (Black)
M-9 M-1
N-5
N-5
DT-T DT-T YAZAKI
F-7 M2 AE8 Q8 AC9 AC9 AD7 AB9 M-8 M-8 M-8 M-6 G-2 K-4 A-1 B-2 F-9
CLTP PACKARD CM CN3 CN4 CN5 CN6

DT-T (Green)
DT-T DT-T DT-T DT-T
Input shaft speed sensor Intermediate shaft speed sensor Output shaft speed sensor
Solenoid for transmission 1st clutch
HD465-7, HD605-7
20-347
(10)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin CN7 CN8 CN9 CN10 CN11 CN12 CN13 CN14 CN15 CN16 CN17 CN18 CN19 CN20 CN21 CN22 CN23 CN24 CNS1 CNS2 CNS3 COM D01 D02 D03 D04 D05 D07 D08 DL DPC1 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T
DT-T (Brown) DT-T (Green) DT-T (Black) One-pin connector
Address Location
System diagram TM N-6 M-6 N-6 M-6 N-6 M-6 N-6 M-5 M-5 M-7 N-6 M-7 N-7 M-7 N-7 M-8 M-7 M-7 H-8 B-9 A-9 E-7 C-7 B-2 H-8 BK PLM MON VHMS ASR
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 2 12 12 12 1 2 2 2 2 2 2 2 12 20 18 12 18 12
Fill switch for transmission 1st clutch Solenoid for transmission 2nd clutch Fill switch for transmission 2nd clutch Solenoid for transmission R clutch Fill switch for transmission R clutch
AB9 AB9 AA9 AA9 AA9 AA9 AA9 AA9 Z9 Z8 Z8 Y8 Y7 Z8 Z8 Z5 AA5 AC5
Solenoid for transmission 3rd clutch

Fill switch for transmission 3rd clutch
Solenoid for transmission 4th clutch

Fill switch for transmission 4th clutch
Solenoid for transmission L clutch

Fill switch for transmission L clutch Solenoid for transmission H clutch Fill switch for transmission H clutch Solenoid for torque converter lockup clutch Fill switch for torque converter lockup clutch Torque converter intermediate pressure sensor Torque converter oil temperature sensor Transmission valve oil temperature sensor Intermediate connector (Power window switch) Intermediate connector (Gear shift lever) Intermediate connector (Parking brake switch)
Air conditioner wiring harness Diode Diode Diode Diode Diode Diode Diode Intermediate connector Machine monitor Machine monitor Machine monitor Machine monitor Machine monitor
M3 W8 W8 W8 M6 V8 P2 W8 X6 P8 P1 P1 P8 Q1 I-9 E-9 D-9 C-1 I-9 E-9 C-1 K-5 C-9 F-8 F-8 A-8 A-1 L-5 C-9 F-8 A-1 F-8
DT-T DT-T DT-T DT-T DT-T DT-T DT-T

DT-T (Black)
I-9 F-1 F-1
E-1 I-9 I-9
AMP070
A-7 A-6 A-6 A-5 A-5 F-1
DPC2A AMP070 DPC2B AMP070 DPC3A AMP070 DPC4 AMP070
20-348
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin DPC6 DPC7 DSL DSR DT7 DT8 E E01 E02A E02B E03 E04 E05 E06 E07 E08 E09 E10 E11A E11B E12A E12B E13A E13B E15 E16A E16B E17A E17B E2B ECM A ECM B EG4 ENG ER AMP040 X DT-T DT-T Terminal Terminal DT-T DT-T DT-T DT-T Terminal Terminal DT-T DT-T Terminal Terminal Terminal Terminal Terminal Terminal
DTHD (#4) DTHD (#4)
Address Location
System diagram TM BK PLM MON VHMS ASR
8 4 1 1 12 4 1 1 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 40 40 12 8 1
Machine monitor
Software rewriting connector (Machine monitor)
O7 N3 F1 T2 T2 J2 L-9 AE7 AH1 AH1 AF1 AH5 C2

AE6, AF1
Door switch (Left) Door switch (Right) Intermediate connector Intermediate connector Emergency steering motor Alternator Starting motor Starting motor Engine speed sensor Oil level switch (If equipped) Oil filter switch Alternator Compressor Diode Alternator Grounding Heater relay Ribbon heater Heater relay Ribbon heater Intermediate connector Intermediate connector Grounding Grounding Grounding Diode Diode Diode Engine controller Engine controller Intermediate connector Intermediate connector Grounding
D-2
F-1
H-1 H-2 G-2
N-3 M-3 M-2 N-3 M-3 H-9
L-4
K-3
N-7
H-1
N-4 N-7
AF8 AG9 AE6 AG9 AJ9 AH9 AJ9 AG9 AG1 AG1 AI2 AI9 AH9 AJ8 AJ8 AE5 AG5 AG9 V9 AJ7
C9, C8, E9, G9
H-1
N-3
F-3 F-2 F-3 F-1 I-2 H-2 G-1 F-3 F-2 F-3 F-2 A-3 A-8 C-8
N-5 N-4 N-4 N-4 K-5 K-5 M-3 N-5 N-4 N-5 N-4
Terminal Terminal Terminal DT-T DT-T DT DRC26 DRC26

DT-T (Brown) DT-T (Gray)
L-1 L-1
K-8 K-8
M-4 M-4 B-3
H-2 I-1
H-3 J-8
J-7 H-8
J-3 J-7
M-7 M-8
Terminal
HD465-7, HD605-7
20-349
(10)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin ER1 ER2 ER3 FBC FL01 FL04 FL05 FLB FLL Terminal Terminal Terminal M DT-T YAZAKI DT-T 1 1 1 6 2 2 2 1 1 2 6 2 2 2 2 2 2 1 1 1 1 1 1 2 1 1 6 2 2 1 1 1 1 Grounding Grounding Grounding
Address Location
System diagram TM D-8 BK F-7 C-1 B-7 F-1 PLM MON VHMS ASR
P1 X7 O2 N3 B3 B3 B2 R1 R1 AF9 N1 B7 X6 X7 X7 X7 X6 AE7 AE7 C9 C9 S1 AF8 K3 M4 M4 O7 AJ7 L5 Q8 A4 A4 F-6 E-2 J-4 E-1 E-1 K-2 K-1 A-1 H-6
A-8
Front brake cutting switch Radiator coolant level sensor Washer motor Air conditioner dual switch Flasher Flasher Fuel temperature sensor Fog lamp switch (If equipped) Air cleaner clogging sensor Spare terminal Spare terminal Spare terminal Spare terminal Spare terminal Fuel shut-off valve Fuel shut-off valve + Fuse box (30 A) Fuse box (120 A x 2)
G-9 H-9 M-1 L-1 A-4 A-4
FLTP PACKARD FOG FR01 FS2 FS3 FS4 FS5 FS8 FSO FSO+ FUA FUB G G G21 GND H01 H10 H20 HAZ HEAT HEPC HES HN HN1A HN1B M DT-T
One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector
C-9 G-9
Terminal Terminal Terminal Terminal

L-9 L-9
I-9
L-9
N-8
I-9 H-1 B-7 K-1 L-8 M-4
Terminal Terminal DT-T

Grounding Engine block GND Steering flow switch Heater unit Heater unit Hazard switch Heater control Hoist EPC valve Grounding Horn switch Horn valve Horn valve
M DT DT-T Terminal
One-pin connector
G-9 J-2 L-2
D-9 L-9 L-9
20-350
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin HN2A HN2B HSL HSL HSOL HTA HTB IMPR IMTP J01 J02 J03 J04 J05 J07 J08 J09 J10 JC01 JC02 JC03 JC04 JC11 JC12 JC13 JC14 JC15 JCA JCB JCC JCD JCE JCF JCG JT1 DT-T DT-T DT-T
DT-T (Gray) DT-T (Black)
Address Location
1 1 4 4 3 8 8 3 2 9 31 31 31 31 14 31 31 31 6 8 8 8 6 6 8 8 6 8 8 8 8 8 8 8 6
Horn valve Horn valve Intermediate connector Hoist lever potentiometer Hoist selector valve Intermediate connector Intermediate connector Intake air pressure sensor Intake air temperature sensor Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
A4 A3 V3 V3 L5 L6 L6 AF8 AF8 I2 I2 I2
H1, AN6 H1, AN6
D-1 D-1 L-2 I-8 I-8 B-1 B-1 G-4 G-3 F-6 F-6 F-6 H-7 H-7 H-6 H-5 F-5 F-5 F-5 G-6 G-4 A-4 A-5 A-5 A-6 E-9 E-9 F-9 G-9 H-9 K-1 K-1 L-1 E-1 K-6 K-6 K-6 K-7 J-8 K-8 C-1 B-1 B-1 B-1 D-1 A-3 J-1 A-1 A-2 A-1 A-2 A-3 F-1 C-1 C-1 C-1 C-1 E-1 F-1 G-1 G-1 G-1 G-1 H-1 I-1 L-7 L-7 L-6 M-3 M-3 A-2 K-1 K-1 L-7 M-4 F-4 F-4 H-4 H-3 G-3 I-5 I-5 H-4 H-3 G-7 G-6 G-5 G-4 G-4 G-4 C-5 C-4 C-4 C-3 I-6 I-6 I-5 I-5 C-7 C-7 C-6 J-3 K-3 J-4 M-2
PACKARD PACKARD
HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 DT

DT (Black) DT (Black) DT (Black)
H1 G1 G1 G1 AI6 AI5 AH5 AG5 AG5 AH5 AI5 AI6 AI6 X5 X5 X5 X4 X4 S9 V3 AD7
DT DT
DT (Black) DT (Black)
DT
DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black)
DT-T
HD465-7, HD605-7
20-351
(10)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin JT2 LINK LKO LKO LP LS M MON1 MON2 MON3 MS11 MS12 MS21 MS22 MS31 MS32 DT-T DT DT-T DT-T
DT (Gray)
Address Location
System diagram TM J-1 BK PLM MON VHMS ASR
6 6 2 2 12 3 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 21 3 16
Joint connector Data link crossover Intermediate connector Lever kick-out solenoid Intermediate connector Rheostat Emergency steering motor Rear view monitor (If equipped) Rear view monitor (If equipped) Rear view monitor (If equipped)
Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller)
AD7 AJ6 U3 V3 I2 M1 F-7
J-3
K-7 D-1 D-1
H-8
K-2 D-9
M Terminal
One-pin connector One-pin connector One-pin connector
K-9 N7 N7 O7 U9 U9 U9 U9 U9 V3 AE5
M8, N9 M8, N9 M8, O9 M8, O9 M8, O9 N8, O8 N8, O8
I-9 I-9 I-9 A-4 A-4 A-4 A-4 A-4 A-4 B-1 A-5 A-5 A-5 A-5 A-5 A-5 A-4
M M M M M M
OLPR PACKARD OP1 OP2 OP3 OP4 OP5 OP6 OP7 OPS PL01 PL02 PL03 PL04 PL05 PL06 PL07 PM1 PM3 PM4 M M M M M M M DT-T M M
One-pin connector One-pin connector One-pin connector One-pin connector
Engine oil pressure sensor

Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector
Seat heater Left head lamp (LOW) Left head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (If equipped) Grounding VHMS wiring harness Pitch angle sensor VHMS wiring harnes
T2 D1 D2 E1 E1 E1 D1 D2 T9 X7 T9 I-8 E-7 D-8

D-8, E-9
J-1 J-1 K-1 K-1 K-1 J-1 K-1 D-7 A-4 C-8
F-6, H-6 F-7, H-7
Terminal MIC DT-T S (Natural color)
20-352
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin PM5 PM6 PM7 PM7 PM8 PM9 PM10 PM11 PMLA MIC AMP040 AMP AMP BENDIX MIC
S (Natural
Address Location
System diagram TM E-9 BK PLM A-9 D-9 A-9 MON VHMS G-8 G-8 H-8 ASR
13 12 9 9 5 21 16 21 12 3 6 21 2 2 1 1 1 1 1 2 2 3 1 6 1 1 1 5 5 5 5 6 6 5 5
Payload meter controller Payload meter controller VHMS wiring harnes Payload meter controller Connector VHMS wiring harness VHMS wiring harnes Intermediate connector Intermediate connector Fuel pump pressure sensor Intermediate connector Intermediate connector Right head lamp (LOW) Right head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (Optional) Grounding Parking brake solenoid Parking brake switch Fuel pump actuator Power window motor (Left) Power mode switch Power window motor (Right)
T9 U9 I-8
E-9
N7 N7 T9 T9 V9 H9 AF5 D8 AJ7 A5 A4 A5 A5 A5 A6 A4 L6 K3 AF5 I2 M4 C7 J-9 H-1 AB4 AB3 AB3 AB3 AB2 AC4 AB4 AB3 H-8 E-1 B-1 G-7 B-2 B-2 A-9 D-1 D-1 D-1 A-8 D-1 F-1 G-9 F-1 L-3 L-3 F-4 H-4 J-7 K-9 J-9 K-9 K-9 K-9 J-9 K-8 C-1 I-3 I-7 E-9 E-9 K-5 H-7 H-6
color) MIC
DT-T (Gray)
PMPR PACKARD PMRA POW PR01 PR02 PR03 PR04 PR05 PR06 PR07 PSOL PSW DT-T HD30 M M
One-pin connector One-pin connector One-pin connector One-pin connector
Terminal DT-T DT-T
PUMP PACKARD PWL PWM PWR R R R01 R02 R03 R04 R05 R06 R07 R08
One-pin connector
M
Relay Relay Relay Relay Relay Relay Relay Relay
Engine starting relay Transmission Neutral relay Parking brake relay Brake lamp relay (RL) Backup lamp, buzzer relay Fog lamp relay AISS relay Brake lamp relay (CTR)
HD465-7, HD605-7
20-353
(10)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin R09 R10 R11 R14 R15 R16 R17 R19 R21 R22 R25 R29 R30 R32 R33 R34 R35 R37 R40 R43 R44 R45 RAD RAIL RDC RE1 RE2 RE3 RE4 RESW RETV RL RL2 RP RPR Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay YAZAKI Relay Relay Relay Relay YAZAKI YAZAKI Relay Relay Relay Relay Relay YAZAKI
PACKARD
Address Location
System diagram TM BK A-9 A-7 D-1 A-8 B-2 C-1 C-1 A-8 A-6 B-1 B-1 C-1 B-1 B-3 E-8 H-9 H-9 PLM MON VHMS E-1 ASR
5 5 5 5 5 6 5 5 6 5 11 5 5 5 6 7 7 5 6 5 5 5 9 3 9 2 2 2 2 2 2 2 1 6 3
Brake lamp timer relay PLM GDL relay Horn relay Brake cutting relay Transmission cutting relay Hazard relay 1 Hazard relay 2 Parking brake safety relay Side lamp relay Rotary lamp relay Power window relay Head lamp Hi relay Head lamp Lo relay Dust indicator relay Parking brake manual switch Power window switch (Left) Power window switch (Right) Auto preheater relay Payload meter relay (If equipped)
Green outside pilot lamp relay of payload meter Yellow outside pilot lamp relay of payload meter Red outside pilot lamp relay of payload meter
AB2 AC4 AC4 AB4 A2 AB1 AC1 AC4 AC4 AD3 AC1 AD2 AD1 AC1 R9 S1 S9 AD3 AD2 AD2 AD2 AD1 O2 AF5 O2 S9 S9 P8 P8 L4 L4 E9 G9 A6 AI6 C-1 A-7 D-1 G-8 B-3
A-6 A-5 A-5 A-5
AM/FM radio Fuel rail actuator Cassette stereo Resistor Resistor Resistor Resistor Retarder switch Retarder valve Room lamp Room lamp 2 Intermediate connector Fuel rail pressure sensor
YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI DT-T DT-T YAZAKI

One-pin connector
C-9
A-8
F-9 F-9 L-1 L-1 N-1
DT-T
PACKARD
K-8
20-354
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin RT2 RT6 RT7 RT8 RTL S01 S02 S03 S04 S05 SBS SDE SF1 SF2 SIG SLG SLG SLL SLR Terminal Terminal Terminal Terminal DT-T DT-T DT-T DT-T DT-T DT-T DT-T M
DT-T (Green)
Address Location
1 1 1 1 6 2 2 2 2 2 2 6 12 2 31 1 1 1 1 5 2 2 4 12 6 2 2 3 2 3 3 3 3 2 6
Emergency steering timer Emergency steering timer Emergency steering timer Emergency steering timer Retarder potentiometer Service brake switch Secondary brake switch
Front brake cutting solenoid (If equipped) Auto suspension solenoid 1 (If equipped) Auto suspension solenoid 2 (If equipped)
M4 M5 M5 M4 P8 B7 E9 E9 F9 F9 U2 N2 R9 Q9 AJ7 C8 J2 J2 C7 T1 AJ8 AJ8 A-1 A-1 C-6 C-5 F1 G9 F9 P1 X7 H1 B7 L8 J9 G9 H9 I-9 J-8 F-9 B-1 H-1 G-9 K-5 K-5 K-5 K-6 K-5 K-5 A-9 F-6 H-4 J-7 I-8 I-2 G-2 J-9 J-5 B-3 B-9 A-7 B-2 H-9 C-9 G-2 G-2 G-2 H-2 H-1 F-1 N-2 N-2 C-8
Seat belt switch Side lamp switch (If equipped) Shift lever Shift lever Intermediate connector Grounding Grounding Side lamp (If equipped) Side lamp (If equipped) S-NET monitor Engine speed sensor (Master) Engine speed sensor (Backup) Spare connector 1 Spare connector 2 Spare connector 3 Speaker (Left) Speaker (Right) Steering speed sensor Pitch angle sensor
Suspension oil pressure sensor(FL) (If equipped) Suspension oil pressure sensor(FR) (If equipped) Suspension oil pressure sensor(RL) (If equipped) Suspension oil pressure sensor(RR) (If equipped)
DT-T HD30 Terminal Terminal M M
S-NET MS3102A 14S SP1 SP2 SPA1 SPA2 SPA3 SPL SPR SR2 SR3 SUFL SUFR SURL SURR T01 T02
PACKARD PACKARD
DT-T DT-T DT-T YAZAKI YAZAKI X X DT-T DT-T DT-T DT-T DT-T DT-T
Fuel level gauge sensor Retarder oil temperature sensor
HD465-7, HD605-7
20-355
(10)
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin T05 T1 TEST TG TG2 Terminal Terminal
Address Location
System diagram TM BK K-1 I-3 F-5 PLM MON VHMS ASR
1 1 1 1 1 3 21 31 2 3 6 8 6 6 12 2 2
Grounding Grounding TEST switch Tachograph Tachograph Timing rail actuator Intermediate connector Intermediate connector Transmission oil filter sensor Timing rail pressure sensor Brake lamp timer Intermediate connector Front wiper motor Front wiper relay Wiper switch Wheel speed sensor (RL) Wheel speed sensor (RR)
I9 AC9 V8 S9 S9 AG9 AD8 AD8 J3 AI6 X7 C2 Q1 R1 Q8 K1 K1 C-1 D-1 H-5 H-5 I-9
TIMG PACKARD TM2 TM3 TMF TPR TR VHM WFM WFR WPS WSRL WSRR HD30 HD30 DT-T
PACKARD
J-4
DT-T (Black)
E-1
M Relay
DT-T (Black)
A-4 A-3 B-3 B-9 C-9
DT-T DT-T
VHMS controller related CAN1 DLSW EG4 GDL GR1 GR2 HM-12
HM-21A HM-21B HM-22A HM-22B HM-23A HM-23B
DT-T Terminal DT-T DT-T Terminal Terminal DT-T DT DT DT DT DT-T DT-T DT DT DT-T DT-T
3 1 12 12 1 1 3 2 2 2 2 3 3 2 2 3 3
VHMS intermediate connector Ground level download box VHMS intermediate connector Ground level download box intermediate connector Ground level download box Ground level download box Blow-by sensor Exhaust temperature sensor Exhaust temperature sensor
Exhaust temperature sensor - amp intermediate connector Exhaust temperature sensor - amp intermediate connector VHMS - exhaust temperature amp intermediate connector VHMS - exhaust temperature amp intermediate connector
AU2 AO1 AV3 AP4 AP2 AP2 AM6 AN8 AN7 AR8 AQ7 AR8 AQ7 AN1 AM1 AU2 AQ6
E-5 A-7 E-6 A-6 A-7 A-7 B-4 B-2 B-2 J-2 J-2 J-2 J-2 B-4 B-8 H-8 I-8
HM-31 HM-35 HM50 HM55
Engine oil temperature sensor Ambient temperature sensor Short connector Short connector
20-355-1
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ConType Numnector of ber No. connector of pin HM81 M 8 2 2 20 18 12 18 12 14 10 1 1 14 10 5 5 21 16 21 4 12 5 8 5 1
Address Location
VHMS - Orbcomm controller intermediate connector
System diagram TM BK PLM MON VHMS ASR L-3 H-8 H-8 I-8 J-8 J-8 J-8 K-8 K-8 L-8 B-7 B-7 K-2 L-2 A-7 K-4 F-7, H-7 F-6, H-6 E-5 C-6 C5 A-7 B-4 K-4 A-7
AT2 AQ2 AR2 AS8 AT7 AU7 AT8 AS8 AU7 AT8 AP3 AP3 AS2 AS2 AP2 AQ6 AV3 AU7 AV6 AO6 AO6 AP3 AM6 AT2 AP2
HM-2130 YAZAKI HM-2140 YAZAKI
Resistor Resistor VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller
Ground level download box lamp terminal Ground level download box lamp terminal
HM-CN1 AMP070
HM-CN2A AMP070 HM-CN2B AMP070 HM-CN3A AMP070 HM-CN3B AMP070 HM-CN4A AMP070 HM-CN4B AMP070
LM1 LM2
ORB-A ORB-B
Terminal Terminal AMP070 AMP070 MS MS MIC S MIC DT-T DT-T MS DT-T MS Terminal
Orbcomm controller Orbcomm controller

Ground level download box PLM connector
PDL PLM PM1 PM4 PM11 SPA1 SPA2 VDL VHM VHMS WAKE
PLM II download connector PLM II intermediate connector PLM II intermediate connector VHMS intermediate connector
Ambient temperature sensor intermediate connector Ground level download box intermediate connector
Ground level download box VHMS connector Blow-by, oil temperature sensor intermediate connector
VHMS download connector Ground level download box
HD465-7, HD605-7
20-355-2
(10)
TROUBLESHOOTING
ABS control related

Connec- Type Numtor of ber No. connector of pin ABS ABS1 ABS1 ABS2 ABS2 ABS3 ABS3A ABS3B ABS4 ABS4 ABS5 ABS5A ABS6 ABS7 ABS8 ABSFL ABSFR ABSRL ABSRR BPFL BPFR BPRL BPRR BRC3B BRC4 BRC5A CHK CVF CVR CVSF CVSR DA1 FOGF FOGM J06 JABS RABS RABS2 S01F S01M S02F S02M WSFL WSFR WSRL2 WSRR2 M MIC DT-T MIC DT-T DT-T 040 040 040 DT-T DT 040 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T 040 040 040 Yazaki DT-T DT-T DT-T DT-T DT-T M M HD30 DT-T KES1 KES1 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T 6 17 6 21 8 6 20 16 12 6 6 20 6 6 6 2 2 2 2 3 3 3 3 16 12 20 6 2 2 3 3 2 12 6 6 31 12 6 6 3 3 3 3 2 2 2 2 Address Location ABS system switch ABS controller Joint connector ABS controller Joint connector Joint connector ABS controller ABS controller ABS controller Joint connector Joint connector ABS controller Joint connector Joint connector Joint connector ABS valve ABS valve ABS valve ABS valve Brake oil pressure Brake oil pressure Brake oil pressure Brake oil pressure Retarder controller Retarder controller Retarder controller System check switch ABS cut solenoid ABS cut solenoid ABS cut switch ABS cut switch Diode Machine monitor Fog lamp switch Fog lamp switch Intermediate connector Intermediate connector ABS cut relay ABS cut valve relay Service brake switch Service brake switch Secondary brake switch Secondary brake switch Wheel speed sensor Wheel speed sensor Wheel speed sensor Wheel speed sensor P1 C-1 A-6 F-1 Y4 Z4 Y1 J-9 C-1 A-5 A-5 A-4 D-1 H-1
System diagram TM BK PLM MON VHMS ASR E-9 ABS BK7 BR3 BF9 BR3 BD2 BE2 BR8 BQ9 BR8 BE2 BF3 BR8 BG8 BH8 BE9 AX9 AX9 BH7 BF9 AW9 AX9 BH8 BG9 BO9 BP9 BQ9 BL8 AZ8 BG9 AY8 BH8 BE9 P1 BM1 BK8 BD1 BA9 BS7 BS7 BC1 AZ1 BC9 BC9 BC1 AY7 BG9 BF9
O2
DPC2B AMP070
20-355-3
(12)
HD465-7, HD605-7
TROUBLESHOOTING
CONNECTOR ARRANGMENT LOCATION
CONNECTOR ARRANGEMENT LOCATION
20-356
(5)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-357
(5)
TROUBLESHOOTING
20-358
(1)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-359
(1)
TROUBLESHOOTING
20-360
(1)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-361
(1)
TROUBLESHOOTING
VHMS control related

(1/2)
20-362
(2)
HD465-7, HD605-7
TROUBLESHOOTING
(2/2)
HD465-7, HD605-7
20-363
(2)
TROUBLESHOOTING
ABS control related

(1/2)
20-364
(12)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-365
(12)
TROUBLESHOOTING
(2/2)
20-366
(12)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-367
(12)
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)
Electrical system diagram related engine control ...................................................................................... 20-404 Information in troubleshooting table ............................................................................................................ 20-406 [C111KT] Abnormality in engine controller memory ............................................................................ 20-408 [C112LK] Abnormality in timing rail actuator ....................................................................................... 20-408 [C113KZ] Abnormal current in timing rail actuator system .................................................................. 20-409 [C115KZ] Abnormality in engine speed sensor 2 systems .................................................................. 20-410 [C116KX] Abnormally high level in timing rail pressure sensor system ............................................... 20-412 [C117KX] Abnormally low level in timing rail pressure sensor system ................................................ 20-413 [C118KX] Abnormally high level in fuel pump pressure sensor system ............................................... 20-414 [C119KX] Abnormally low level in fuel pump pressure sensor system ................................................ 20-415 [C121LC] Abnormality in engine speed sensor 1 systems .................................................................. 20-415 [C122KX] Abnormally high level in boost pressure sensor system ...................................................... 20-416 [C123KX] Abnormally low level in boost pressure sensor system ....................................................... 20-417 [C131KX] Abnormally high level in throttle sensor system .................................................................. 20-418 [C132KX] Abnormally low level in throttle sensor system .................................................................... 20-420 [C135KX] Abnormally high level in engine oil pressure sensor system ............................................... 20-421 [C141KX] Abnormally low level in engine oil pressure sensor system ................................................ 20-422 [C143ZG] Lowering of engine oil pressure ........................................................................................... 20-422 [C144KX] Abnormally high level in engine coolant temperature sensor system .................................. 20-423 [C145KX] Abnormally low level in engine coolant temperature sensor system ................................... 20-424 [C148KX] Abnormality in FM throttle: Out of input signal range .......................................................... 20-425 [C151NS] Rise of engine coolant temperature ..................................................................................... 20-426 [C153KX] Abnormally high level in air intake temperature sensor system ........................................... 20-427 [C154KX] Abnormally low level in air intake temperature sensor system ............................................ 20-428 [C221KX] Abnormally high level in atmospheric pressure sensor system ........................................... 20-429 [C222KX] Abnormally low level in atmospheric pressure sensor system ............................................ 20-430 [C234NI] Over-speed .......................................................................................................................... 20-430 [C254KZ] Abnormal voltage of fuel shut-off valve................................................................................. 20-431 [C259FS] Abnormality in fuel shut-off valve ......................................................................................... 20-432 [C261NS] Abnormal rise of fuel temperature ....................................................................................... 20-432 [C263KX] Abnormally high level in fuel temperature sensor system ................................................... 20-433 [C265KX] Abnormally low level in fuel temperature sensor system ..................................................... 20-434 [C316KZ] Abnormal current of fuel pump actuator .............................................................................. 20-435 [C318LK] Abnormality in fuel pump actuator ....................................................................................... 20-436 [C346KT] Abnormality in power-down unit of engine controller ........................................................... 20-437 [C423L6] Abnormality in in-range of timing rail pressure sensor system ............................................ 20-439 [C431L4] Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed) ................................................................. 20-441 [C432L5] Error in idle validation process ( *See separate list (L5))...................................................... 20-443 [C441KX] Abnormally low level in battery voltage system .................................................................. 20-445 [C442KG] Abnormally high level in battery voltage system .................................................................. 20-445 [C451KX] Abnormally high level in fuel rail pressure sensor system ................................................... 20-446 [C452KX] Abnormally low level in fuel rail pressure sensor system .................................................... 20-447 [C455KZ] Abnormal current of fuel rail actuator .................................................................................. 20-448
HD465-7, HD605-7
20-401
(10)
[C467LK] [C468LK] [C514LK] [C551L4]
Abnormality in timing rail actuator control ........................................................................... 20-449 Abnormality in fuel rail actuator control ................................................................................ 20-449 Abnormality in fuel rail actuator .......................................................................................... 20-450 Abnormality in idle validation switch system: *See separate list (L4) (Either signal voltage of 2 systems is not sensed) ............................................................... 20-451 [C554L6] Abnormality in in-range of fuel rail pressure sensor system ................................................ 20-453 ENG-1 Engine does not start............................................................................................................ 20-455 ENG-2 Failure in preheating ............................................................................................................. 20-459 a) Engine is not preheated................................................................................................... 20-459 b) Preheating is actuated even under non-actuation conditions for preheating................... 20-462 ENG-3 AISS function does not work normally .................................................................................. 20-464 a) When AISS switch is set in AUTO, LOW SPEED control is selected.............................. 20-464 b) When AISS switch is set in LOW SPEED, AUTO control is selected.............................. 20-465
20-402
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL

Engine serial No. : 310169 310414
20-404
(9)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-405
(2)
TROUBLESHOOTING
Engine serial No. : 310415 310798
20-405-1
(8)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-405-2
(8)
TROUBLESHOOTING
Engine serial No. : 310799 and up
20-405-3
(8)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-405-4
(8)
TROUBLESHOOTING
INFORMATION IN TROUBLESHOOTING TABLE

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Action code Display on panel Failure code Controller code Display on panel Display on panel Trouble Trouble in machine
Contents of trouble Contents of trouble detected by monitor panel or controller Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble or monitor panel Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting <Contents of description> Standard value in normal state to judge possible causes Remarks on judgment <Troubles in harness> Disconnection Connector is connected imperfectly or harness is broken. Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. Short circuit Independent harnesses are in contact with each other abnormally.
Possible causes Possible causes of trouble and standard value (Given numbers are refer<Precautions for troubleshooting> 3 in normal state ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter indicate priority) Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. 4 If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained 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
(10)
HD465-7, HD605-7
TROUBLESHOOTING
Related electrical circuit diagram
Part of electric circuit diagram related to trouble Connector No.: Indicates (Model Number of pins) and (Color). Arrows ( ): Indicate rough location of connector in machine.
PHENOMENON CODE TABLE

a Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon code KA KB KK KQ KR KT KX KY KZ MA MB MW NS ZG ZK Contents Disconnection in wiring Short circuit Source voltage reduction/ input Type select signal inconsistency Defective communication Abnormality in controller Outside input signal range Short circuit with power source (Hot short) Disconnection or short circuit Malfunction Performance reduction Sliding Overheat Oil pressure reduction Coolant level reduction Phenomenon code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents Fill signals at two or more channels which are not set as combination are turned ON at the same time. Fill signal is ON when command current to ECMV is OFF. Fuel pressure is above maxim specified value. Object part is uncontrollable. ON and OFF signals at two systems are inconsistent. Engine rotation signal, terminal C signal, oil pressure switch signal, coolant temperature sensor signal, etc. are inconsistent with operation state or stop state. Analog signals in two systems are inconsistent. rpm signals in two systems are inconsistent. Switch is pressed for usually unthinkable long time. Fill signal is OFF when command current to ECMV is ON.
HD465-7, HD605-7
20-407
(10)
TROUBLESHOOTING
[C111KT], [C112LK]
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY

Action code E03 Failure code Controller code C111KT ENG Trouble Abnormality in engine controller memory (Engine controller system)
Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.
Action of controller Flashes warning lamp and turns on alarm buzzer.

Problem that Engine cannot be started. appears on machine Related information Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value 1 Defective engine controller in normal state
Standard value in normal state/Remarks on troubleshooting Reset according to following procedure. If failure code E is displayed at this time, engine controller is defective. 1) Keep starting switch at OFF position for 5 seconds. 2) Run engine at low idle. 3) Check failure code.
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR

Action code E03 Failure code Controller code C112LK ENG Trouble Abnormality in timing rail actuator (Engine controller system)
Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble Judgment value (for reference):
Error is above 400 mm3/st or below 750 mm3/st (When coolant temperature is below 0C). Action of controller Flashes warning lamp and turns on alarm buzzer. Limits engine speed to 1,500 rpm.
Problem that Engine speed lowers. appears on machine Related information Method of reproducing failure code: Start engine.
Cause 1 Defective related systems
Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first.
Possible causes and standard value 3 Defective timing rail actuator Check timing rail actuator directly for defective operation. in normal state Clogging of timing rail actua4 Check timing rail actuator screen directly for clogging. tor screen 5 Breakage of injector O-ring 6 Defective engine controller Check injector O-ring directly for breakage.
Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
20-408
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C113KZ]
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM

Action code E03
Contents of trouble
Failure code Controller code C113KZ ENG
Trouble
Abnormal current in timing rail actuator system (Engine controller system)
Current in timing rail actuator is out of normal range. Normal range (for reference): 0.40 0.35 A (When engine is stopped)
Action of controller Flashes warning lamp and turns on alarm buzzer. Engine output lowers. Problem that appears on machine Exhaust gas becomes white.
Related information
Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator. Method of reproducing failure code: Turn starting switch ON (or start engine). Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective timing rail actuator (Internal trouble) TIMG (male) Between (A) (C) Between (A), (C) chassis ground Resistance 79z Min. 100 kz
Possible causes and standard value in normal state
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (1) 2 (Disconnection in wiring or Resistance Max. 10 z TIMG (female) (A) defective contact in connecWiring harness between ECMA (female) (20) tor) Resistance Max. 10 z TIMG (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (1) TIMG (female) (A) with wiring harness around Resistance Min. 1 M z it Wiring harness between ECMA (female) (20) TIMG (female) (C) with wiring harness around Resistance Min. 1 M z it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (1) (20) Wiring harness between (1), (20) wiring harness around it Resistance 79z Min. 1 M z
Circuit diagram related to timing rail actuator
HD465-7, HD605-7
20-409
(11)
TROUBLESHOOTING
[C115KZ]
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS

Action code E03 Failure code Controller code C115KZ ENG Trouble Abnormality in engine speed sensor 2 systems (Engine controller system)
Contents of trouble Signal is not input to either of engine speed sensor circuit 2 systems.
Action of controller
Flashes warning lamp and turns on alarm buzzer. Outputs speed signal of 0 rpm.
Problem that Engine stops. appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 01001, 01002: Engine speed) Related information Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor. Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON Defective engine speed sen1 sor (Internal trouble) SP (male) Between (2) (1) and (3) (4) Between (2) (3) Between (1) (4) Between (2), (3) chassis ground 2 Damage of engine speed sensor Check engine speed sensor directly. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMA (female) (27) Resistance Max. 10 z SP (female) (2) Wiring harness between ECMA (female) (28) Resistance Max. 10 z SP (female) (1) Wiring harness between ECMA (female) (37) Resistance Max. 10 z SP (female) (3) Wiring harness between ECMA (female) (38) Resistance Max. 10 z SP (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between ECMA (female) (27) Resistance Min. 1 Mz SP (female) (2) with wiring harness around it Wiring harness between ECMA (female) (28) Resistance Min. 1 Mz SP (female) (1) with wiring harness around it Wiring harness between ECMA (female) (37) Resistance Min. 1 Mz SP (female) (3) with wiring harness around it Wiring harness between ECMA (female) (38) Resistance Min. 1 Mz SP (female) (4) with wiring harness around it aPrepare with starting switch OFF, then start engine and carry out troubleshooting. ECMA (female) 5 Defective engine controller Between (27) (28) Between (27), (28) chassis ground Between (37) (38) Between (37), (38) chassis ground Resistance 1 2 kz Min. 1 Mz 1 2 kz Min. 1 Mz Resistance 1 2 kz Max. 10 z Max. 10 z Min. 10 Mz
20-410
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C115KZ]
Circuit diagram related to engine speed sensor
HD465-7, HD605-7
20-411
(8)
TROUBLESHOOTING
[C116KX]
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM

Action code E03 Failure code Controller code C116KX ENG Trouble Abnormally high level in timing rail pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Flashes warning lamp and turns on alarm buzzer. Action of controller Opens and controls timing rail. Limits engine speed to 1,500 rpm. Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to Problem that appears on machine 1,500 rpm.
Related information
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor. Method of reproducing failure code: Start engine. Cause Defective timing rail pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TPR Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) Resistance Max. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) Resistance Max. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) Resistance Max. 10 z TPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring harness 3 (with another wiring harness)
Wiring harness between ECMA (female) (5) Resistance Min. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) Resistance Min. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) Resistance Min. 1 Mz TPR (female) (C) with wiring harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
4 Defective engine controller
ECMA Between (5) (18) Between (33) (18)
Voltage 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to timing rail pressure
20-412
(11)
HD465-7, HD605-7
TROUBLESHOOTING
[C117KX]
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM

Action code E03 Failure code Controller code C117KX ENG Trouble Abnormally low level in timing rail pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of timing rail pressure sensor circuit is below 0.30 V
Flashes warning lamp and turns on alarm buzzer. Action of controller Opens and controls timing rail. Limits engine speed to 1,500 rpm. Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to Problem that appears on machine 1,500 rpm.
Related information Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C116KX].
HD465-7, HD605-7
20-413
(10)
TROUBLESHOOTING
[C118KX]
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM

Action code E01 Failure code Controller code C118KX ENG Trouble Abnormally high level in fuel pump pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
Problem that appears on machine Related information
Flashes warning lamp and turns on alarm buzzer. Opens and controls fuel pump.
Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor. Method of reproducing failure code: Start engine. Cause Defective fuel pump pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PMPR (male) Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) Resistance Max. 10 z PMPR (female) (A) Wiring harness between ECMA (female) (18) Resistance Max. 10 z PMPR (female) (B) Wiring harness between ECMA (female) (32) Resistance Max. 10 z PMPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) PMPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (18) PMPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (32) PMPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
ECMA (female) Between (5) (18) Between (32) (18)
Resistance 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-414
(11)
HD465-7, HD605-7
TROUBLESHOOTING
[C119KX], [C121LC]
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM

Action code E01 Failure code Controller code C119KX ENG Trouble Abnormally low level in fuel pump pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
Problem that appears on machine
Flashes warning lamp and turns on alarm buzzer. Opens and controls fuel pump.
Cause
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS

Action code E01 Failure code Controller code C121LC ENG Trouble Abnormality in engine speed sensor 1 systems (Engine controller system)
Contents of trouble Signal is not input to both of engine speed sensor circuit 2 systems.

Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 01001: Engine speed) Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C115KZ].
HD465-7, HD605-7
20-415
(10)
TROUBLESHOOTING
[C122KX]
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM

Action code E03 Action of controller When machine is accelerated suddenly, exhaust gas color is bad. Problem that appears on machine Engine output rises.
Related information
Failure code Controller code C122KX ENG
Trouble
Abnormally high level in boost pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of boost pressure sensor circuit is above 4.72 V.
Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor. Method of reproducing failure code: Start engine. Cause Defective boost pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. IMPR (male) Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (6) Resistance Max. 10 z IMPR (female) (A) Wiring harness between ECMA (female) (17) Resistance Max. 10 z IMPR (female) (B) Wiring harness between ECMA (female) (35) Resistance Max. 10 z IMPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (6) IMPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) IMPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (35) IMPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
ECMA Between (6) (17) Between (35) (17)
Voltage 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to boost pressure sensor
20-416
(11)
HD465-7, HD605-7
TROUBLESHOOTING
[C123KX]
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM

Action code E03 Action of controller
Problem that Engine output lowers. appears on machine Related information Method of reproducing failure code: Start engine.
Trouble
Abnormally low level in boost pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.
Cause
HD465-7, HD605-7
20-417
(10)
TROUBLESHOOTING
[C131KX]
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM

Action code E03 Failure code Controller code C131KX ENG Trouble Abnormally high level in throttle sensor system (Engine controller system)
Contents of trouble Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4.80 V.
Flashes warning lamp and turns on alarm buzzer. Keeps engine speed at constant level.
Problem that Engine output and speed rise suddenly. appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. Related information (Code 31701: throttle potentiometer voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective throttle potentiom1 eter (Internal trouble) AS1 (male) Between (3) (1) Between (3) (2) Between (2) (1) Resistance 4.0 6.0 kz 0.25 7.0 kz 0.25 7.0 kz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMB (female) (26) Resistance Max. 10 z AS1 (female) (3) Wiring harness between ECMB (female) (11) Resistance Max. 10 z AS1 (female) (1) Wiring harness between ECMB (female) (29) Resistance Max. 10 z AS1 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Short circuit of wiring harness between ECMB (female) (26) AS1 (female) (3) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (11) AS1 (female) (1) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (29) AS1 (female) (2) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller ECMB Between (29) (11) Voltage 0.30 4.80 V
20-418
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C131KX]
Circuit diagram related to deceleration potentiometer
HD465-7, HD605-7
20-419
(1)
TROUBLESHOOTING
[C132KX]
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM

Action code E03 Failure code Controller code C132KX ENG Trouble Abnormally low level in throttle sensor system (Engine controller system)
Contents of trouble Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.
Flashes warning lamp and turns on alarm buzzer. 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) Method of reproducing failure code: Turn starting switch ON. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C131KX].
20-420
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C135KX]
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM

Action code E01 Failure code Controller code C135KX ENG Trouble Abnormally high level in engine oil pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.

Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor. Method of reproducing failure code: Start engine. Cause Defective engine oil pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OLPR Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (6) Resistance Max. 10 z OLPR (female) (A) Wiring harness between ECMA (female) (17) Resistance Max. 10 z OLPR (female) (B) Wiring harness between ECMA (female) (24) Resistance Max. 10 z OLPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ECMA (female) (6) OLPR (female) (A) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) OLPR (female) (B) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (24) OLPR (female) (C) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller ECMA Between (6) (17) Between (24) (17) Voltage 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to engine oil pressure sensor
HD465-7, HD605-7
20-421
(10)
TROUBLESHOOTING
[C141KX], [C143ZG]
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM

Action code E01 Failure code Controller code C141KX ENG Trouble Abnormally low level in engine oil pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of engine oil pressure sensor circuit is below 0.31 V.

Problem that appears on machine Related information Method of reproducing failure code: Turn starting switch ON.
Cause
[C143ZG] LOWERING OF ENGINE OIL PRESSURE

Action code E03 Failure code Controller code C143ZG ENG Trouble Lowering of engine oil pressure (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 Max. 0.15 MPa {1.5 kg/cm2} at 1,500 rpm Max. 0.18 MPa {1.85 kg/cm2} at 1,800 rpm Max. 0.21 MPa {2.1 kg/cm2} at 2,000 rpm Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that appears on machine Related information Method of reproducing failure code: Start engine.
Cause 1 Defective related systems Possible causes and standard value Defective engine oil presin normal state 2 sure sensor system 3 Defective engine
Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for failure codes [C135KX] and [C141KX]. See Shop Manual for engine (170-3 Series).
20-422
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C144KX]
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C144KX ENG Trouble Abnormally high level in engine coolant temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.

Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor. Method of reproducing failure code: Start engine. Cause Defective engine coolant 1 temperature sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CLTP Between (A) (B) Resistance 600 36 kz
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (22) Resistance Max. 10 z CLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) tor) Resistance Max. 10 z CLTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Short circuit of wiring harness between ECMA (female) (22) CLTP (female) (A) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) CLTP (female) (B) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (22) (17) Resistance 600 36 kz
Circuit diagram related to engine coolant temperature sensor
HD465-7, HD605-7
20-423
(10)
TROUBLESHOOTING
[C145KX]
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C145KX ENG Trouble Abnormally low level in engine coolant temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.

Cause
20-424
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C148KX]
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE

Action code E03 Failure code Controller code C148KX ENG Trouble Abnormality in FM throttle: Out of input signal range
Contents of trouble The frequency of the FM throttle is below 150 Hz or above 400 Hz.
Flashes warning lamp and turns on alarm buzzer. The throttle sensor signal is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).
Problem that The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%). appears on machine Related information
Cause
Standard value in normal state/Remarks on troubleshooting
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) (17) contact) Resistance Max. 10 z ATC3A (female) (5) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and ATC3A. 3) Connect T-adapter. Wiring harness between ECMB (female) (17) ATC3A (female) (5) Resistance between ECMB (female) (17), ATC3A (feMin. 1 Mz male) (5) chassis ground
2 Possible causes and standard value in normal state
Ground fault in wiring harness
1) Turn the starting switch OFF. 2) Disconnect connector ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 3 fective 5) Turn the starting switch ON. Between ATC3A (male) (5) chassis ground 1) Connect all the connectors. 2) Turn the starting switch ON. 4 Engine controller defective Check that the failure code disappears. aIf the failure code does not disappear, replace the engine controller. Frequency 170 380Hz
Circuit diagram related to engine abnormality in FM throttle
HD465-7, HD605-7
20-425
(10)
TROUBLESHOOTING
[C151NS]
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE

Action code E02
Contents of trouble
Failure code Controller code C151NS ENG
Trouble
Rise of engine coolant temperature (Engine controller system)
Engine coolant temperature sensor detected temperature higher than temperature set in controller. Criterion (for reference): Min. 105C
Action of controller Limits fuel injection rate to 50% after 10 seconds.

Cause
Check displayed failure codes. If code related to engine controller is 1 Defective related systems Possible causes displayed, carry out troubleshooting for it first. and standard value Defective engine coolant in normal state 2 Carry out troubleshooting for failure codes [C144KX] and [C145KX]. temperature sensor system 3 Defective engine See Shop Manual for engine (170-3 Series).
20-426
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C153KX]
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C153KX ENG Trouble Abnormally high level in air intake temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of air intake temperature sensor circuit is above 4.88 V.

Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor. Method of reproducing failure code: Start engine. Cause Defective air intake temper1 ature sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. IMTP (female) Between (A) (B) Resistance 36 600 z
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (23) Resistance Max. 10 z IMTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) tor) Resistance Max. 10 z IMTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (23) IMTP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) IMTP (female) (B) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (23) (17) Resistance 36 600 z
Circuit diagram related to air intake temperature sensor
HD465-7, HD605-7
20-427
(10)
TROUBLESHOOTING
[C154KX]
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C154KX ENG Trouble Abnormally low level in air intake temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.

Cause
20-428
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C221KX]
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)

Action code E03 Failure code Controller code C221KX ENG Trouble Abnormally high level in atmospheric pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V

Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor. Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting AAPR Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
Defective atmospheric pres1 sure sensor (Internal trouble)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (6) Resistance Max. 10 z AAPR (female) (A) Wiring harness between ECMA (female) (17) Resistance Max. 10 z AAPR (female) (B) Wiring harness between ECMA (female) (34) Resistance Max. 10 z AAPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (6) AAPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) AAPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (34) AAPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller ECMA Between (6) (17) Between (34) (17) Voltage 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to atmospheric pressure sensor
HD465-7, HD605-7
20-429
(10)
TROUBLESHOOTING
[C222KX] , [C234NI]
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM

Action code E03 Failure code Controller code C222KX ENG Trouble Abnormally low level in atmospheric pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.

Cause
[C234NI] OVER-SPEED
Action code E02
Contents of trouble
Failure code Controller code C234NI ENG
Trouble
Over-speed (Engine controller system)
Engine speed sensor detected speed higher than speed set in controller. Criterion (for reference): Min. 2,400 rpm
Action of controller Closes fuel rail actuator fully (Cuts out fuel).
Cause Possible causes and standard value 1 Defective related systems in normal state 2 Defective engine
Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. See Shop Manual for engine (170-3 Series).
20-430
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C254KZ]
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE

Action code E03 Failure code Controller code C254KZ ENG Trouble Abnormal voltage of fuel shut-off valve (Engine controller system)
Contents of trouble Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 z).
Action of controller Turns off power for fuel shut-off valve.

Problem that Engine stops. appears on machine Related information Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective fuel shut-off valve (Internal trouble)
FSO (Valve side) Between (+) () Between (+) chassis ground
Resistance 23 40 z 100 kz
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (30) Resistance Max. 10 z FSO (wiring harness side) (+) defective contact in connecWiring harness between FSO (wiring harness Possible causes tor) Resistance Max. 10 z side) () chassis ground and standard value in normal state aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harWiring harness between ECMA (female) (30) ness FSO (wiring harness side) (+) with wiring har- Resistance Min. 1 Mz 3 ness around it (with another wiring harness) Wiring harness between FSO (wiring harness side) () chassis ground with wiring harness Resistance Min. 1 Mz around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA Between (30) chassis ground Resistance 23 40 z
Circuit diagram related to fuel shut-off valve
HD465-7, HD605-7
20-431
(10)
TROUBLESHOOTING
[C259FS], [C261NS]
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE

Action code E03 Failure code Controller code C259FS ENG Trouble Abnormality in fuel shut-off valve (Engine controller system)
Contents of trouble Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
Flashes warning lamp and turns on alarm buzzer. Turns off power for fuel shut-off valve.
Problem that Engine cannot be stopped. appears on machine Related information Method of reproducing failure code: Start engine.
2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly. Possible causes Clogging, looseness, breakand standard value Check fuel filter/piping directly for clogging, looseness, breakage, and 3 age, or leakage of fuel filter/ in normal state leakage. piping 4 Trouble in injector 5 Defective engine controller Check inside of injector directly. If causes 1 4 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE

Action code E02
Contents of trouble
Failure code Controller code C261NS ENG
Trouble
Abnormal rise of fuel temperature (Engine controller system)
Fuel temperature sensor detected temperature lower than temperature set in controller. Criterion (for reference): Min. 76C
Action of controller Limits engine speed to 800 rpm after 30 seconds.

Cause 1 Defective related systems Possible causes and standard value Defective fuel temperature in normal state 2 sensor system 3 Defective engine
Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for failure codes [C263KX] and [C264KX]. See Shop Manual for engine (170-3 Series).
20-432
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C263KX]
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C263KX ENG Trouble Abnormally high level in fuel temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel temperature sensor circuit is above 4.95 V.

Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor. Method of reproducing failure code: Turn starting switch ON. Cause Defective fuel temperature 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FLTP (female) Between (A) (B) Resistance 600 36 kz
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (26) Resistance Max. 10 z FLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) tor) Resistance Max. 10 z FLTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (26) FLTP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) FLTP (female) (B) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (26) (17) Resistance 600 36 kz
Circuit diagram related to fuel temperature sensor
HD465-7, HD605-7
20-433
(10)
TROUBLESHOOTING
[C265KX]
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM

Action code E01 Failure code Controller code C265KX ENG Trouble Abnormally low level in fuel temperature sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.

Cause
20-434
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C316KZ]
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR

Action code E01
Contents of trouble
Trouble
Abnormal current of fuel pump actuator (Engine controller system)
Current of fuel pump actuator circuit is out of normal range. Normal range (for reference): 0.40 0.35 A (When engine is stopped)

Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator. Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective fuel pump actuator (Internal trouble) PUMP (male) Between (A) (C) Between (A), (C) chassis ground Resistance 79z Min. 100 kz
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (11) 2 (Disconnection in wiring or Resistance Max. 10 z PUMP (female) (A) defective contact in connecWiring harness between ECMA (female) (40) tor) Resistance Max. 10 z PUMP (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (11) PUMP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (40) PUMP (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (11) (40) Between (11), (40) another wiring harness Resistance 79z Min. 1 Mz
Circuit diagram related to fuel pump actuator
HD465-7, HD605-7
20-435
(10)
TROUBLESHOOTING
[C318LK]
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR

Action code E01
Contents of trouble
Failure code Controller code C318LK ENG
Trouble
Abnormality in fuel pump actuator (Engine controller system)
Displayed pressure of fuel pump is excessively different from actual value. Criteria for difference (for reference): 0.21 MPa {2.1 kg/cm2} (when coolant temperature is 38C)

Problem that Engine speed is unstable. appears on machine Related information Method of reproducing failure code: Start engine.
Clogging, looseness, breakCheck fuel filter and piping directly for clogging, looseness, breakage, 2 age, or leakage of fuel filter/ and leakage. piping 3 Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level fuel level in tank gauge is in red range, supply fuel. Suction resistance of fuel filter may be large. Check fuel filter directly. Negative suction pressure (Tank side) 27 kPa {203 mmHg}
Possible causes and standard value Large suction resistance of 4 in normal state fuel filter 5 6
Trouble in fuel pump actuaFuel pump actuator may malfunction. Check it directly. tor Defective electric system of Carry out troubleshooting for failure codes [C118KX] and [C119KX]. fuel pump pressure sensor Inside of injector may be defective. Check it directly. If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Trouble in injector 8 Defective engine controller
Circuit diagram related to fuel pump actuator
20-436
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C346KT]
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER

Action code E03 Failure code Controller code C346KT ENG Trouble Abnormality in power-down unit of engine controller (Engine controller system)
Contents of trouble Data recorded in power-down unit of engine controller has error.
Action of controller Flashes warning lamp and turns on alarm buzzer. Power-down data (maintenance information, current controller information, engine operating hours, Problem that appears on machine etc.) are lost.
Related information
Charge level of battery can be checked in monitoring mode. (Code: 04301) Method of reproducing failure code: Turn starting switch ON. Cause 1 Defective fusible link (34 A) 2 Defective fuse (FS1-1, FS1-4) Standard value in normal state/Remarks on troubleshooting If fusible link is broken, circuit probably has short circuit with chassis ground. If fuse is broken, circuit probably has short circuit with chassis ground. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMB (female) (3) Resistance Max. 10 z BT2-(6) outlet Wiring harness between ECMA (female) (4), (5) BT2-(30) outlet Resistance Max. 10 z
Possible causes and standard value in normal state Short circuit in wiring harness 4 (with another wiring harness)
Wiring harness between FS1 inlet fusible link Resistance Max. 10 z (FUA) battery relay terminal B aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMB (female) (3) Resistance Min. 1 Mz BT2-(6) outlet with wiring harness around it Wiring harness between ECMA (female) (4), (5) BT2-(30) outlet with wiring harness around it Resistance Min. 1 Mz
Wiring harness between FS1 inlet fusible link battery relay terminal B with wiring harness Resistance Min. 1 Mz around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller ECMA, ECMB Between ECMB (3), (4), (5) ECMA (7), (8) Voltage 17.3 34.7 V
HD465-7, HD605-7
20-437
(10)
TROUBLESHOOTING
[C346KT]
Circuit diagram related to engine controller power supply
20-438
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[C423L6]
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM

Action code E03
Contents of trouble
Failure code Controller code C423L6 ENG
Trouble
Abnormality in in-range of timing rail pressure sensor system (Engine controller system)
Timing rail pressure sensor detected abnormal pressure. Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on Flashes warning lamp and turns on alarm buzzer. Limits high idle speed to 1,500 rpm.
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor. Method of reproducing failure code: Turn starting switch ON. Cause Defective timing rail pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TPR (male) Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) Resistance Max. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) Resistance Max. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) Resistance Max. 10 z TPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) Resistance Min. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) Resistance Min. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) Resistance Min. 1 Mz TPR (female) (C) with wiring harness around it 4 Large suction resistance of fuel filter Suction resistance of fuel filter may be large. Check fuel filter directly. Negative suction pressure (Tank side) 27 kPa {203 mmHg}
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller ECMA (female) Between (5) (18) Between (33) (18) Resistance 4.75 5.25 V 0.42 0.58 V
HD465-7, HD605-7
20-439
(11)
TROUBLESHOOTING
[C423L6]
Circuit diagram related to timing rail pressure sensor
20-440
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[C431L4]
[C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)
Action code E01 Failure code Controller code C431L4 ENG Trouble Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed)
Contents of trouble Both idle validation switch signals 2 and 3 are open (above 4.5 V).
Action of controller (The controller displays action code E01, CHECK/REPAIR.) None in particular. (Since the controller controls according to the throttle sensor signal (potentiometer), Problem that appears on machine no problems appear in the truck body.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AS1. 3) Connect T-adapter.
Between AS1 Idle validation switch defec(male) (4) (5) 1 tive
Release the accelerator pedal "Idle ON".
Resistance Max. 100 z
Press the accelerator pedal Resistance Min. 1 Mz "Idle OFF". Release the accelerator pedal "Idle ON". Resistance Min. 1 Mz
Between AS1 (male) (4) (6)
Press the accelerator pedal Resistance Max. 100 z "Idle OFF".
1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between ECMB (female) (12) Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) contact) Resistance Max. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Wiring harness between ECMB (female) (12) AS1 (female) (6) Wiring harness between ECMB (female) (13) AS1 (female) (5) Wiring harness between ECMB (female) (21) AS1 (female) (4) Resistance between ECMB (female) (12), AS1 (female) Min. 1 M z (6) chassis ground Resistance between ECMB (female) (13), AS1 (female) Min. 1 Mz (5) chassis ground Resistance between ECMB (female) (21), AS1 (female) Min. 1 Mz (4) chassis ground
4 Engine controller defective
1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.
HD465-7, HD605-7
20-441
(10)
TROUBLESHOOTING
[C431L4]
Circuit diagram related to engine idle validation switch
20-442
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C432L5]
[C432L5] ERROR IN IDLE VALIDATION PROCESS ( *SEE SEPARATE LIST (L5))

Action code E03
Contents of trouble
Error in idle validation process: *See separate list (L5) Trouble (Potentiometer signal and switch signal do not agree with each other)
The throttle potentiometer signal of the accelerator pedal is not conformed to idle validation switch signal 2 and signal 3.
Flashes warning lamp and turns on alarm buzzer. The throttle is conformed to the idle validation switch (In idle: 0%, Off idle: 35%). Action of controller If this failure is detected when the throttle sensor signal is on the low speed side (idle side), the throttle is conformed to the throttle sensor.
Problem that The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%). appears on machine Related information
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between ECMB (female) (12) Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) contact) Resistance Max. 1 z AS1 (female) (5) Possible causes and standard value in normal state Wiring harness between ECMB (female) (21) Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Wiring harness between ECMB (female) (12) AS1 (female) (6) Wiring harness between ECMB (female) (13) AS1 (female) (5) Wiring harness between ECMB (female) (21) AS1 (female) (4) Resistance between ECMB (female) (12), AS1 (female) Min. 1 M z (6) chassis ground Resistance between ECMB (female) (13), AS1 (female) Min. 1 Mz (5) chassis ground Resistance between ECMB (female) (21), AS1 (female) Min. 1 Mz (4) chassis ground
4 Slottle sensor defective
1) Turn the starting switch OFF. 2) Disconnect connector AS1. 3) Connect T-adapter. 4) Connect connector. 5) Startin switch ON. Between AS1 (male) (1) (2) Release the accelerator pedal "Idle ON". Press the accelerator pedal "Idle OFF". Voltage Voltage 0.35 0.55V 3.55 3.75V
HD465-7, HD605-7
20-443
(10)
TROUBLESHOOTING
[C432L5]
Cause Possible causes and standard value 5 Engine controller defective in normal state
Standard value in normal state/Remarks on troubleshooting 1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.
Circuit diagram related to engine idle validation process
20-444
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C441KX], [C442KG]
[C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM

Trouble
Abnormally low level in battery voltage system (Engine controller system)
Contents of trouble Voltage of controller power supply circuit is below 12 V.
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT].
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM

Failure code Controller code C442KG ENG
Trouble
Abnormally low level in battery voltage system (Engine controller system)
Contents of trouble Voltage of controller power supply circuit is below 38 V.
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT].
HD465-7, HD605-7
20-445
(10)
TROUBLESHOOTING
[C451KX]
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM

Action code E03 Failure code Controller code C451KX ENG Trouble Abnormally high level in fuel rail pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
Flashes warning lamp and turns on alarm buzzer. Opens and controls fuel rail.
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. Method of reproducing failure code: Start engine. Cause Defective fuel rail pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPR Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) Resistance Max. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) Resistance Max. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) Resistance Max. 10 z RPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) Resistance Min. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) Resistance Min. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) Resistance Min. 1 Mz RPR (female) (C) with wiring harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller ECMA Between (5) (18) Between (31) (18) Voltage 4.75 5.25 V 0.42 0.58 V
Circuit diagram related to fuel rail pressure sensor
20-446
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C452KX]
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM

Action code E03 Failure code Controller code C452KX ENG Trouble Abnormally low level in fuel rail pressure sensor system (Engine controller system)
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
Flashes warning lamp and turns on alarm buzzer. Reduces current for fuel rail actuator to 0 A.
Cause
HD465-7, HD605-7
20-447
(10)
TROUBLESHOOTING
[C455KZ]
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR

Action code E03
Contents of trouble
Trouble
Abnormal current of fuel rail actuator (Engine controller system)
Current of fuel rail actuator circuit is out of normal range. Normal range (for reference): 0.40 0.35 A (When engine is stopped) Flashes warning lamp and turns on alarm buzzer. Limits engine speed to 1,500 rpm.
Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator. Method of reproducing failure code: Turn starting switch ON or start engine. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective fuel rail actuator (Internal trouble) RAIL (male) Between (A) (C) Between (A), (C) chassis ground Resistance 79z Min. 100 kz
aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (3) Resistance Max. 10 z 2 (Disconnection in wiring or RAIL (female) (A) defective contact in connecWiring harness between ECMA (female) (10) tor) Resistance Max. 10 z RAIL (female) (C) Short circuit in wiring harness 3 (with another wiring harness) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (3) Resistance Min. 1 Mz RAIL (female) (A) with wiring harness around it Wiring harness between ECMA (female) (10) Resistance Min. 1 Mz RAIL (female) (C) with wiring harness around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ECMA (female) Between (3) (10) Between (3), (10) another wiring harness Resistance 79z Min. 1 Mz
Circuit diagram related to fuel rail actuator
20-448
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C467LK], [C468LK]
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL

Action code E03
Contents of trouble
Trouble
Abnormality in timing rail actuator control (Engine controller system)
Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot be obtained. Flashes warning lamp and turns on alarm buzzer. Limits engine speed to 1,500 rpm.
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C112LK].
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL

Action code E03
Contents of trouble
Trouble
Abnormality in fuel rail actuator control (Engine controller system)
Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be obtained. Flashes warning lamp and turns on alarm buzzer. Limits maximum injection rate to 217 mm3/st.
Possible causes 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 6 Defective engine controller Injector O-ring may be broken. Check it directly.
Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HD465-7, HD605-7
20-449
(10)
TROUBLESHOOTING
[C514LK]
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR

Action code E03
Contents of trouble
Trouble
Abnormality in fuel rail actuator (Engine controller system)
Displayed injection rate of fuel rail is excessively different from actual injection rate. Criterion (for reference): Difference is 600 mm3/st for 50 msec or 250 mm3/st for 200 msec. Flashes warning lamp and turns on alarm buzzer. Limits maximum injection rate to 217 mm3/st.
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C468LK].
20-450
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C551L4]
[C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)
Action code E01 Failure code Controller code C551L4 ENG Trouble Abnormality in idle validation switch system: *See separate 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).
Flashes warning lamp and turns on alarm buzzer. Controller sets engine speed to low idle.
Problem that Engine speed is kept at low idle. appears on machine Related information
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between ECMB (female) (12) Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) contact) Resistance Max. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Wiring harness between ECMB (female) (12) AS1 (female) (6) Wiring harness between ECMB (female) (13) AS1 (female) (5) Wiring harness between ECMB (female) (21) AS1 (female) (4) Resistance between ECMB (female) (12), AS1 (female) Min. 1 M z (6) chassis ground Resistance between ECMB (female) (13), AS1 (female) Min. 1 Mz (5) chassis ground Resistance between ECMB (female) (21), AS1 (female) Min. 1 Mz (4) chassis ground
1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.
HD465-7, HD605-7
20-451
(10)
TROUBLESHOOTING
[C551L4]
Circuit diagram related to idle validation switch
20-452
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[C554L6]
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM

Action code E03
Contents of trouble
Trouble
Abnormality in in-range of fuel rail pressure sensor system (Engine controller system)
Fuel rail pressure sensor detected abnormal pressure. Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on Flashes warning lamp and turns on alarm buzzer. Limits maximum injection rate to 270 mm3/st
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. Method of reproducing failure code: Turn starting switch ON. Cause Defective fuel rail pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPR Between (A) (B) Between (C) (B) Voltage 4.75 5.25 V 0.42 0.58 V
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) Resistance Max. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) Resistance Max. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) Resistance Max. 10 z RPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) Resistance Min. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) Resistance Min. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) Resistance Min. 1 Mz RPR (female) (C) with wiring harness around it 4 Large suction resistance of fuel filter Suction resistance of fuel filter may be large. Check fuel filter directly. Negative suction pressure (Tank side) 27 kPa {203 mmHg}
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller ECMA Between (5) (18) Between (31) (18) Voltage 4.75 5.25 V 0.42 0.58 V
HD465-7, HD605-7
20-453
(11)
TROUBLESHOOTING
[C554L6]
Circuit diagram related to fuel rail pressure sensor
20-454
(1)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-1
ENG-1 ENGINE DOES NOT START

Action code Not set Failure code Controller code Not set ENG Trouble Engine does not start
Contents of trouble Engine does not start.
Action of controller None in particular.

Problem that Engine does not start. appears on machine Related information
If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it first. Cause 1 Battery defective Standard value in normal state/Remarks on troubleshooting Specific gravity Voltage 1) Turn the starting switch OFF. 2) Replace R01 with normal one. 3) Turn the starting switch ON. When engine starting relay (R01) No is replaced, is failure repaired? Yes 1) Turn the starting switch OFF. 2) Disconnect connector R01. 3) Check R01. Between R01 (male) (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R01. 3) Check R01. 4) Apply voltage between R01 (male) (1) (2). Between R01 (male) (3) (6) Apply 24 V between (1) (2). Do not apply voltage between (1) (2). Resistance Min. 1 Mz Resistance Max. 1 z Relay (R01) normal Relay (R01) defective Min. 1.26 Min. 25 V
Engine starting relay (R01) defective
1) Turn the starting switch OFF. 2) Replace R02 with normal one. 3) Turn the starting switch ON. When transmission neutral relay (R02) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R02. 3) Check R02. Between R02 (male) (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R02. 3) Check R02. 4) Apply voltage between R02 (male) (1) (2). Between R02 (male) (3) (6) Apply 24 V between (1) (2). Do not apply voltage between (1) (2). Resistance Min. 1 Mz Resistance Max. 1 z No Yes Relay (R02) normal Relay (R02) defective
Transmission neutral relay (R02) defective
4 Diode (D01) defective
1) Turn the starting switch OFF. 2) Replace diode (D01). 3) Turn the starting switch to the START position. Failure is not repaired. Failure is repaired. Diode (D01) is normal. Diode (D01) is defective.
HD465-7, HD605-7
20-455
(10)
TROUBLESHOOTING
ENG-1
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. Wiring harness between batVoltage between battery tertery battery terminal 01 minal 01 (B), 03 (B), 02 (M), 20 30 V (B), 03 (B), 02 (M), and 04 and 04 (M) chassis ground (M)
1) Turn the starting switch OFF. Disconnection of wiring har- 2) Disconnect fuse BT3 terminal (9) battery relay terminal 02 (M) and 04 (M). 5 ness between battery relay and related wiring harness Wiring harness between bat- Resistance between battery tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) Max. 1 z (M) fuse BT3 (9) fuse BT3 (10) 1) Turn the starting switch OFF. 2) Disconnect the negative (-) terminal of the battery relay. Wiring harness between the negative (-) termiResistance Max. 1 z nal of the battery relay chassis ground 1) Turn the starting switch to the START position. Disconnection in wiring har- Wiring harness between bat6 ness related to starting mo- tery relay terminal 02 (M), 04 Voltage between starting motor terminal B chassis tor terminal B (M) starting motor terminal ground B 1) Turn the starting switch OFF. 2) Replace diode (D01). 3) Turn the starting switch to the START position. Failure is repaired. Failure is not repaired. Diode (D01) is normal. Diode (D01) is defective.
20 30 V
Hot short in wiring harness of starting motor terminal R Wiring harness between diode (D01), starting motor terminal R, alternator terminal R
1) Turn the starting switch OFF. 2) Disconnect connector ATC3B, diode (D01), alternator terminal R, and starting motor terminal R. 3) Turn the starting switch ON. Voltage between diode (D01), starting motor termiMax. 12 V nal R (on the harness side), chassis ground
1) Turn the starting switch ON. Alternator (Regulator) defecVoltage between starting motor terminal R chassis tive ground 1) Turn the starting switch OFF. 2) Replace diode (D08). 3) Turn the starting switch to the START position. Failure is not repaired. Failure is repaired.
Max. 12 V
Diode (D08) is normal. Diode (D08) is defective.
20-456
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-1
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R01, battery relay terminal 14 (BR), 12 (BR), and starting switch terminals BR and C.
Wiring harness between starting switch terminal B Disconnection in wiring har- battery relay terminals 01 (B) and 03 (B). ness 11 (Disconnection or defective contact) Wiring harness related to starting switch Wiring harness between starting switch terminal BR battery relay terminal 14 (BR), 12 (BR)
Resistance between starting switch terminal B battery Max. 1 z relay terminal 01 (B) and 03 (B) Resistance between starting switch terminal BR battery Max. 1 z relay terminal 14 (BR), 12 (BR)
aMeasure at starting switch terminal BR (+ side of tester) with a tester in the diode range. Wiring harness between starting switch terminal C R01 (female) (3) Resistance between starting switch terminal C R01 (fe- Max. 1 z male) (3)
1) Turn the starting switch OFF. 2) Disconnect connectors R01 and R02, fuse BT3 terminal (10), and starting motor terminal S. 3) Connect T-adapter. Disconnection in wiring harness Possible causes (Disconnection or defective and standard value 12 contact) in normal state Wiring harness related to engine starting relay (R01) Wiring harness between Resistance between fuse fuse BT3 terminal (10) R01 BT3 terminal (10) R01 (fe- Max. 1 z (female) (1) male) (1) Wiring harness between R01 (female) (2) R02 (female) (6) Wiring harness between R01 (female) (6) starting motor terminal S Resistance between R01 (female) (2) R02 (female) (6) Resistance between R01 (female) (6) starting motor terminal S Max. 1 z
Max. 1 z
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector R02 and S2 (connector of shift lever side). 3) Connect T-adapter. ness (Disconnection or defective 13 contact) Wiring harness related to transmission neutral relay (R02) Wiring harness between R02 (female) (1) S2 (female) (4) Resistance between R02 (female) (1) S2 (female) (4) Max. 1 z
Wiring harness between Resistance between R02 R02 (female) (2), (3) chas- (female) (2), (3) chassis sis ground ground 1) Disconnect the starting switch terminals. 2) Check the starting switch. Turn the starting switch to the START position. 1) Check the starting motor. Resistance between terminals B C
Max. 1 z
14 Starting switch defective
Max. 1 z
15 Starting motor defective
If the check result of the starting motor is normal, the starting motor is normal.
HD465-7, HD605-7
20-457
(10)
TROUBLESHOOTING
ENG-1
Circuit diagram related to engine does not start
20-458
(1)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-2
ENG-2 FAILURE IN PREHEATING

a) Engine is not preheated
Action code Not set Failure code Controller code Not set ENG Trouble 1. Failure in preheating a) Engine is not preheated
Contents of trouble Engine is not preheated. (Engine coolant temperature is below 0C.)

Problem that Engine is not preheated. appears on machine Related information
If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors E11A, E12A, E11B, and E12B. 3) Check the disconnected connectors. Between E11A chassis ground Between E12A opposite Intake air heater relay defec- terminal of relay switch 1 tive When relay is ON When relay is OFF When relay is ON When relay is OFF Resistance 19 25 z Resistance Max. 1 z Resistance Min. 1M z Resistance 19 25 z Resistance Max. 1 z Resistance Min. 1 Mz
Between E11B chassis ground Between E12B opposite terminal of relay switch
Intake air heater (Ribbon heater) defective
1) Turn the starting switch OFF. 2) Disconnect the heater terminal. 3) Check the heater. Between heater terminal chassis ground 1) Turn the starting switch OFF. 2) Replace R37 with a normal relay. 3) Turn the starting switch ON. When the automatic preheater relay (R37) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R37. 3) Check connector R37. Between R37 (male) (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R37. 3) Check connector R37. 4) Apply voltage between R37 (male) (1) (2). Between R37 (male) (3) (6) Apply 24 V between (1) (2). Do not apply voltage between (1) (2). Resistance Min. 1M z Resistance Max. 1 z No Yes Relay (R37) is normal. Relay (R37) is defective. Resistance 0.17 0.27z
Automatic preheater relay (R37) defective
1) Turn the starting switch OFF. Diode (E17A, E17B) defec- 2) Replace diode (E17A, E17B). 4 tive Failure is not repaired. Failure is repaired.
HD465-7, HD605-7
20-459
(10)
TROUBLESHOOTING
ENG-2
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ECMA, R37, E11A, E11B, E12A, E12B, and fuse BT4 terminal (4). 3) Connect T-adapter. Wiring harness between ECMA (female) (2) R37 (female) (1) Resistance between ECMA (female) (2) R37 (female) (1) Resistance between R37 (female) (2) chassis ground Resistance between R37 (female) (5) E11A, E11B Max. 1 z
Wiring harness between Disconnection in wiring har- R37 (female) (2) chassis ness ground 5 (Disconnection or defective Wiring harness between contact) R37 (female) (5) E11A, E11B
Max. 1 z
Max. 1 z
Wiring harness between Resistance between fuse fuse BT4 terminal (4) R37 BT4 terminal (4) R37 (fe(female) (3) male) (3) Wiring harness between bat- Resistance between battery tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) (M) E12A, E12B E12A, E12B 1) Turn the starting switch OFF. 2) Disconnect connector ECMA. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Engine coolant temperature: Max. 0C Between At the heater operation ECMA (2) (7), (8) At the heater un operation Voltage Voltage
Max. 1 z
Max. 1 z
20 30V Max. 1 V
20-460
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-2
Circuit diagram related to preheating
HD465-7, HD605-7
20-461
(1)
TROUBLESHOOTING
ENG-2
b) Preheating is actuated even under non-actuation conditions for preheating

Action code Not set Failure code Controller code Not set ENG Failure in preheating Trouble b) Preheating is actuated even under non-actuation conditions for preheating
Contents of trouble Preheating is actuated even under non-actuation conditions for preheating.

Problem that Preheating is actuated even under non-actuation conditions for preheating. appears on machine Related information
If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors E11A, E12A, E11B, and E12B. 3) Check the disconnected connectors. Between E11A chassis ground Between E12A opposite Intake air heater relay defec- terminal of relay switch 1 tive When relay is ON When relay is OFF When relay is ON When relay is OFF Resistance 19 25 z Resistance Max. 1 z Resistance Min. 1 Mz Resistance 19 25 z Resistance Max. 1 z Resistance Min. 1 Mz
Between E11B chassis ground Between E12B opposite terminal of relay switch
Possible causes and standard value in normal state 2 Hot short in wiring harness
1) Turn the starting switch OFF. 2) Disconnect the connector. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ECMA (female) (2) R37 (female) (1) Wiring harness between R37 (female) (5) E11A, E11B Wiring harness between AC5A (female) (20) HES (a ) Voltage between ECMA (female) (2), R37 (female) (1) chassis ground Voltage between R37 (female) (5), E11A, E11B chassis ground Voltage between AC5A (female) (20), HES chassis ground Max. 1 V
Max. 1 V
Max. 1 V
Measure only on E12A side for wiring harness marked with (a). 1) Turn the starting switch OFF. 2) Disconnect connector ECMA. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Engine coolant temperature: Max. 0 C Between At the heater operation ECMA (2) (7), (8) At the heater un operation Voltage Voltage 20 30V Max. 1 V
20-462
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-2
Circuit diagram related to preheating time
HD465-7, HD605-7
20-463
(1)
TROUBLESHOOTING
ENG-3
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY

a) When AISS switch is set in AUTO, LOW SPEED control is selected
Action code Not set Failure code Controller code Not set Not set When AISS switch is operated, AISS function does not work normally Trouble a) When AISS switch is set in AUTO, LOW SPEED control is selected
Contents of trouble When AISS switch is set in AUTO, LOW SPEED control is selected

Problem that When AISS switch is set in AUTO, LOW SPEED control is selected appears on machine Related information Failure code is not indicated.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AISS. 3) Check the connector. Between AISS (male) (1) (2) Set the AISS switch in AUTO Resistance Max. 1 z Set the AISS switch in LOW. Resistance Min. 1 Mz
1 AISS switch defective
1) Turn the starting switch OFF. 2) Replace R07 with normal one. 3) Turn the starting switch ON. When AISS relay (R07) is replaced, is failure corrected? 1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay Between R07 (male) (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay. 4) Apply voltage between R07 (male) (1) (2). Between R07 (male) (3) (6) Apply 24 V between (1) (2). Do not apply 24 V between (1) (2). Resistance Min. 1 Mz Resistance Max. 1 z No Yes Relay (R07) is normal Relay (R07) is defective
2 AISS relay (R07) defective
1) Turn the starting switch OFF. 2) Disconnect connectors AISS, R07, fuse BT2 terminal (2). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (2) AISS Resistance Max. 1 z ness (female) (1) 3 (Disconnection or defective Wiring harness between AISS (female) (2) contact) Resistance Max. 1 z R07 (female) (1) Wiring harness between R07 (female) (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ECMB Set the AISS switch in AUTO. (33) chassis ground Set the AISS switch in LOW. Voltage Voltage 20 30 V Max. 1 V Resistance Max. 1 z
20-464
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ENG-3
b) When AISS switch is set in LOW SPEED, AUTO control is selected

Action code Not set Failure code Controller code Not set Not set When AISS switch is operated, AISS function does not work normally Trouble b) When AISS switch is set in LOW SPEED, AUTO control is selected
Contents of trouble When AISS switch is set in LOW SPEED, AUTO control is selected

Problem that When AISS switch is set in LOW SPEED, AUTO control is selected appears on machine Related information Failure code is not indicated.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AISS. 3) Check the connector. Between AISS (male) (1) (2) Set the AISS switch in AUTO Resistance Max. 1 z Set the AISS switch in LOW Resistance Min. 1 Mz
1 AISS switch defective
1) Turn the starting switch OFF. 2) Replace R07 with normal one. 3) Turn the starting switch ON. When AISS relay (R07) is replaced, is failure corrected? 1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay Between R07 (male) (1) (2) Possible causes and standard value in normal state Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay. 4) Apply voltage between R07 (male) (1) (2). Between R07 (male) (3) (6) Apply 24 V between (1) (2). Do not apply 24 V between (1) (2). Resistance Min. 1 Mz Resistance Max. 1 z No Yes Relay (R07) is normal Relay (R07) is defective
2 AISS relay (R07) defective
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector R07. ness 3) Connect T-adapter. 3 (Disconnection or defective Wiring harness between R07 (female) (3) contact) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors AISS and R07. 3) Connect T-adapter. Wiring harness beWiring harness between AISS (female) tween AISS (female) (2), R07 (female) (1) (2) R07 (female) (1) chassis ground Wiring harness beWiring harness between ECMB (female) tween ECMB (female) (33), R07 (female) (6) (33) R07 (female) (6) chassis ground
Resistance Max. 1 z
4 Hot short in wiring harness
Voltage
Max. 1 V
Voltage
Max. 1 V
HD465-7, HD605-7
20-465
(10)
TROUBLESHOOTING
ENG-3
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ECMB Set the AISS switch in AUTO. (33) chassis ground Set the AISS switch in LOW. Voltage Voltage 20 30 V Max. 1 V
Possible causes and standard value 5 Engine controller defective in normal state
Circuit diagram related to low speed, auto control
20-466
(1)
HD465-7, HD605-7
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE)
Electrical system diagram related to transmission control .......................................................................... 20-503 Information in troubleshooting table ....................................................................................................... 20-504 Phenomenon code table ........................................................................................................................ 20-505 [1380MW] Lockup clutch: Slip (MW)................................................................................................... 20-506 [1500L0] Detection of double engagement: *See separate list (L0) ................................................. 20-507 [15B0NX] Clogging of transmission oil filter: Clogging (NX) .............................................................. 20-508 [15E0KM] R to F gear shift abuse 1: Mistake in operation or setting (KM) ........................................ 20-509 [15E7KM] R to F gear shift abuse 2: Mistake in operation or setting (KM) ......................................... 20-509 [15G0MW] R clutch: Slip (MW)............................................................................................................ 20-510 [15H0MW] Hi clutch: Slip (MW) ........................................................................................................... 20-511 [15J0MW] Lo clutch: Slip (MW) ........................................................................................................... 20-513 [15K0MW] 1st clutch: Slip (MW).......................................................................................................... 20-515 [15L0MW] 2nd clutch: Slip (MW) ........................................................................................................ 20-516 [15M0MW] 3rd clutch: Slip (MW) ......................................................................................................... 20-517 [15N0MW] 4th clutch: Slip (MW) ......................................................................................................... 20-518 [15SBL1] R clutch solenoid: *See separate list (L1).......................................................................... 20-519 [15SBMA] R clutch solenoid: Malfunction (MA) .................................................................................. 20-520 [15SCL1] Hi clutch solenoid: *See separate list (L1)......................................................................... 20-521 [15SCMA] Hi clutch solenoid: Malfunction (MA) ................................................................................. 20-522 [15SDL1] Lo clutch solenoid: *Seee separate list (L1) ...................................................................... 20-523 [15SDMA] Lo clutch solenoid: Malfunction (MA)................................................................................. 20-524 [15SEL1] 1st clutch solenoid: *See separate list (L1) ....................................................................... 20-525 [15SEMA] 1st clutch solenoid: Malfunction (MA)................................................................................ 20-526 [15SFL1] 2nd clutch solenoid: *See separate list (L1) ...................................................................... 20-527 [15SFMA] 2nd clutch solenoid: Malfunction (MA)............................................................................... 20-528 [15SGL1] 3rd clutch solenoid: *See separate list (L1) ....................................................................... 20-529 [15SGMA] 3rd clutch solenoid: Malfunction (MA) ............................................................................... 20-530 [15SHL1] 4th clutch solenoid: *See separate list (L1) ....................................................................... 20-531 [15SHMA] 4th clutch solenoid: Malfunction (MA)................................................................................ 20-532 [15SJL1] Lockup clutch solenoid: 15SJ (L1)..................................................................................... 20-533 [15SJMA] Lockup clutch solenoid: 15SJ (MA) ................................................................................... 20-534 [2F00KM] Parking brake: Mistake in operation or setting (KM).......................................................... 20-535 [989A00] Engine overrun prevention command signal: Operation (00) ............................................ 20-537 [989AKZ] Engine overrun prevention command signal: Disconnection or short circuit (KZ) ............. 20-538 [AA10NX] Air cleaner element: Clogging (NX) ................................................................................... 20-539 [AB00MA] Alternator: Malfunction (MA).............................................................................................. 20-541 [B@BCZK] Lowering of radiator water: Lowering of level (ZK) ............................................................ 20-543 [D1BOKZ] Transmission controller cutout: Disconnection or short circuit (KZ) .................................. 20-544 [D5ZMKZ] Disconnection, grounding fault, or short circuit in engine output mode command line: Disconnection or short circuit (KZ) .................................................................................... 20-546 [DAQ0KK] Transmission controller: Lowering of source/input voltage (KK) ....................................... 20-547 [DAQ1KK] Main power line of transmission controller: Lowering of source/input voltage (KK) .......... 20-549 [DAQ2KK] Transmission controller load power line: Lowering of source/input voltage (KK) ............. 20-551 [DAQ3KK] Direct line of transmission controller battery: Lowering of source/input voltage (KK) ........ 20-553 [DAQ9KM] Transmission controller wiring harness: Mistake in operation or setting (KM) .................. 20-554 [DAQ9KQ] Transmission controller wiring harness: Disagreement of model selection signals (KQ) .. 20-555 [DAQAKQ] Transmission controller rotary switch: Disagreement of model selection signals (KQ) ..... 20-556 [DAQSMA] Transmission controller: Malfunction (MA) ........................................................................ 20-556
HD465-7, HD605-7
20-501
(10)
TROUBLESHOOTING
[DDTGKA] [DDTHKA] [DDTJKA] [DDTKKA] [DDTLKA] [DDTMKA] [DDTNKA] [DDTPKA] [DF10KA] [DF10KB] [DGF1KX] [DGT1KX] [DHT5KX] [DHT5L6] [DJF1KA] [DK11KX] [DLE2KA] [DLE2LC] [DLF1KA] [DLF1LC] [DLF2KA] [DLF2LC] [DLT3KA] [DLT3LC] [DXH1KA] [DXH1KB] [DXH2KA] [DXH2KB] [DXH3KA] [DXH3KB] [DXH4KA] [DXH4KB] [DXH5KA] [DXH5KB] [DXH6KA] [DXH6KB] [DXH7KA] [DXH7KB] [DXHHKA] [DXHHKB] TM-1 TM-2
Lockup clutch fill switch: Disconnection (KA) .................................................................... 20-557 Hi clutch fill switch: Disconnection (KA)............................................................................. 20-558 Lo clutch fill switch: Disconnection (KA) ............................................................................ 20-559 1st clutch fill switch: Disconnection (KA) ........................................................................... 20-560 2nd clutch fill switch: Disconnection (KA) .......................................................................... 20-561 3rd clutch fill switch: Disconnection (KA)........................................................................... 20-562 R clutch fill switch: Disconnection (KA) ............................................................................. 20-563 4th clutch fill switch: Disconnection (KA) ........................................................................... 20-564 Shift lever: Disconnection (KA) .......................................................................................... 20-565 Shift lever: Short circuit (KB) ............................................................................................. 20-569 Transmission valve oil temperature sensor: Out of input signal range (KX) ...................... 20-572 Torque converter oil temperature sensor: Out of inputsignal range (KX) .......................... 20-574 Torque converter oil pressure sensor: Out of input signal range (KX) .............................. 20-575 Torque converter oil pressure sensor: See separate list (L6) ........................................... 20-577 Fuel level sensor: Disconnection (KA) ............................................................................... 20-578 Throttle angle sensor: Out of input signal range (KX) ....................................................... 20-579 Engine speed sensor: Disconnection (KA) ........................................................................ 20-581 Engine speed sensor: *See separate list (LC) ................................................................... 20-582 Transmission input shaft speed sensor: Disconnection (KA) ............................................ 20-583 Transmission input shaft speed sensor: *See separate list (LC) ....................................... 20-584 Transmission intermediate shaft speed sensor: Disconnection (KA) ................................ 20-585 Transmission intermediate shaft speed sensor: *See separate list (LC) .......................... 20-586 Transmission output shaft speed sensor: Disconnection (KA) .......................................... 20-587 Transmission output shaft speed sensor: *See separate list (LC) ..................................... 20-588 Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA) .................. 20-590 Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB) ......................... 20-591 Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA) ......................... 20-592 Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB) ............................... 20-593 Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA) ........................ 20-595 Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB) ............................... 20-596 Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA) ....................... 20-598 Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB) ............................... 20-599 Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA) ...................... 20-600 Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB) ............................. 20-601 Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA) ....................... 20-602 Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB) .............................. 20-603 Disconnection in output circuit of R clutch solenoid: Disconnection (KA) .......................... 20-604 Short circuit in output circuit of R clutch solenoid: Short circuit (KB) ................................. 20-605 Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA) ....................... 20-606 Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB) .............................. 20-607 Fuel level gauge does not operate normally (It always indicates "FULL") ........................ 20-608 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
(2)
HD465-7, HD605-7
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

a For details of this page, see page 90-19.
HD465-7, HD605-7
20-503
(2)
TROUBLESHOOTING

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
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
20-504
(10)
HD465-7, HD605-7
TROUBLESHOOTING

HD465-7, HD605-7
20-505
(10)
TROUBLESHOOTING
[1380MW]
[1380MW] LOCKUP CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 1380MW TM
Lockup clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the lockup clutch ECMV, the value calculated from the signals of the engine 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.
The lockup operation is reset and the gear cannot be shifted. Problem that 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. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connector CN20. Lockup clutch ECMV defec- 3) Connect T-adapter. 1 tive Between CN20 (male) (1) (2)
Resistance 5 15 z
Between CN20 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN10. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) Resistance Max. 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) Resistance Max. 1 z CN20 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (10) Resistance 5 15 z ATC2 (female) (20)
20-506
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[1500L0]
[1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0)

Action code E03
Contents of trouble
Failure code Controller code 1500L0 TM
Trouble Detection of double engagement: *See separate list (L0)
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. The transmission cutout relay is turned OFF. Problem that appears on machine The gear is set in Neutral.
Related information
Another failure (Clutch pressure control valve system failure code: 15S*L1) occurs simultaneously with this failure. Cause Standard value in normal state/Remarks on troubleshooting
Clutch pressure control Possible causes 1 valve system failure code Perform troubleshooting by the indicated failure code. and standard value (15S*L1) is indicated. in normal state Transmission controller de2 Perform troubleshooting by the indicated failure code. fective
HD465-7, HD605-7
20-507
(10)
TROUBLESHOOTING
[15B0NX]
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER: CLOGGING (NX)

Action code E01
Contents of trouble
Failure code Controller code 15B0NX TM
Trouble Clogging of transmission oil filter: Clogging (NX)
When the torque converter oil temperature is above 50C, the signal circuit of the transmission clogging 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". Cause Standard value in normal state/Remarks on troubleshooting
Clogging of transmission fil1 Clean or replace. ter 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A, TMF and CN10. Transmission filter clogging 3) Connect T-adapter. 2 sensor defective Resistance Max. 1 z Between TMF (male) Filter is normal. (1) (2) Filter is clogged. Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A, TNF, and CN10. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 3 Wiring harness between ATC5A (female) (6) in normal state Resistance Max. 1 z (Disconnection or defective TMF (female) (1) contact) Wiring harness between CJH1 (female) (5) Resistance Max. 1 z TMF (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect conector. 4 fective 5) Turn the starting switch ON. Between ATC5A (6) chassis ground Filter is normal. Filter is clogged. Voltage Voltage Max. 1 V 20 30 V
20-508
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15E0KM], [15E7KM]
[15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM)

Action code Not set
Contents of trouble
Failure code Controller code 15E0KM TM
Trouble R to F gear shift abuse 1: Mistake in operation or setting (KM)
When the output shaft speed is 200 rpm 300 rpm (approx. 5 7 km/h), the gear is shifted from reverse to forward.
Action of controller None in particular. If the machine is used without repairing, it may be broken. Problem that 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).
Possible causes and standard value 1 Abuse in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Change the travel direction after the machine is stopped perfectly.
[15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM)

Action code Not set
Contents of trouble
Failure code Controller code 15E7KM TM
Trouble R to F gear shift abuse 2: Mistake in operation or setting (KM)
When the output shaft speed is above 300 rpm (approx. 7 km/h), the gear is shifted from reverse to forward.
Action of controller None in particular. If the machine is used without repairing, it may be broken. Problem that appears on machine The failure is only recorded in the failure history.
Possible causes and standard value 1 Abuse in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Change the travel direction after the machine is stopped perfectly.
HD465-7, HD605-7
20-509
(10)
TROUBLESHOOTING
[15G0MW]
[15G0MW] R CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15G0MW TM
R clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission 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
This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).
Related information If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure
control valve for a defect. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN10. 3) Connect T-adapter. Between CN10 (male) (1) (2) Resistance 5 15 z Between CN10 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN10. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (5) Resistance Max. 1 z CN10 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) Resistance Max. 1 z CN10 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
1 R clutch ECMV defective
1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (5) ATC2 (female) (15)
Resistance 5 15 z
20-510
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15H0MW]
[15H0MW] HI CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15H0MW TM
Hi clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the Hi clutch ECMV, the value 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 The gear is set in Neutral suddenly during travel. appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure
1 Hi clutch ECMV defective
Resistance 5 15 z
HD465-7, HD605-7
20-511
(10)
TROUBLESHOOTING
[15H0MW]
20-512
(7)
HD465-7, HD605-7
TROUBLESHOOTING
[15J0MW]
[15J0MW] LO CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15J0MW TM
Lo clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the transmission input shaft 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 Lo clutch and pressure
1 Lo clutch ECMV defective
Resistance 5 15 z
HD465-7, HD605-7
20-513
(10)
TROUBLESHOOTING
[15J0MW]
20-514
(7)
HD465-7, HD605-7
TROUBLESHOOTING
[15K0MW]
[15K0MW] 1ST CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15K0MW TM
1st clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 1st clutch ECMV, the value calculated from the signals of the transmission input shaft 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 1st clutch and pressure
1 1st clutch ECMV defective
Resistance 5 15 z
HD465-7, HD605-7
20-515
(10)
TROUBLESHOOTING
[15L0MW]
[15L0MW] 2ND CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15L0MW TM
2nd clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 2nd clutch ECMV, the value calculated from the signals of the transmission input shaft 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 2nd clutch and pressure
control valve for a defect. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connector CN8. 1 2nd clutch ECMV defective 3) Connect T-adapter. Between CN8 (male) (1) (2)
Resistance 5 15 z
Between CN8 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN8. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (4) Resistance Max. 1 z CN8 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) Resistance Max. 1 z CN8 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
Resistance 5 15 z
20-516
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15M0MW]
[15M0MW] 3RD CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15M0MW TM
3rd clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 3rd clutch ECMV, the value calculated from the signals of the transmission input shaft 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 3rd clutch and pressure
1 3rd clutch ECMV defective
Resistance 5 15 z
HD465-7, HD605-7
20-517
(10)
TROUBLESHOOTING
[15N0MW]
[15N0MW] 4TH CLUTCH: SLIP (MW)

Action code E03
Contents of trouble
Failure code Controller code 15N0MW TM
4th clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 4th clutch ECMV, the value calculated from the signals of the transmission input shaft 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 4th clutch and pressure
1 4th clutch ECMV defective
Resistance 5 15 z
20-518
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SBL1]
[15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SBL1 TM
Trouble
R clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)
When the output to the R clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Problem that The gear is set in Neutral suddenly during travel. appears on machine Related information This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN11. 3) Connect T-adapter.
1 R clutch fill switch defective Between CN11 (male) (1) chassis ground
When disResistance Min. 1 Mz engaged When enResistance Max. 1 z gaged
Possible causes and standard value Ground fault in wiring har2 in normal state ness
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN11. 3) Connect T-adapter. Wiring harness between ATC5A (female) (16) CN11 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Resistance between ATC5A (female) (16), CN11 (female) (1) chassis ground Min. 1 Mz
Transmission controller defective
When disResistance Min. 1 Mz Between ATC5A (female) (16) engaged chassis ground When enResistance Max. 1 z gaged
HD465-7, HD605-7
20-519
(10)
TROUBLESHOOTING
[15SBMA]
[15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SBMA TM
R clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the R clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft 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 R clutch and pressure
20-520
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SCL1]
[15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code Hi clutch solenoid: *See separate list (L1) Trouble (Command is OFF and fill switch is ON) 15SCL1 TM When the output to the Hi clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN19. 3) Connect T-adapter. Hi clutch fill switch defective When disResistance Min. 1 Mz Between CN19 (male) (1) chas- engaged sis ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN19. 3) Connect T-adapter. Resistance between ATC5A (female) (12), Wiring harness between ATC5A (female) (12) CN19 (female) (1) CN19 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. When disResistance Min. 1 Mz Between ATC5A (female) (12) engaged chassis ground When enResistance Max. 1 z gaged
Cause
Min. 1 Mz
HD465-7, HD605-7
20-521
(10)
TROUBLESHOOTING
[15SCMA]
[15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA)

Hi clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is E03 15SCMA TM sensed) When a signal is output to the Hi clutch ECMV, the signal from the fill switch is kept OFF and the value 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. Action of controller The controller sets the gear in Neutral. Action code Failure code Controller code
Related information If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure
control valve for a defect. Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN18. 3) Connect T-adapter. Hi clutch ECMV defective Resistance 5 15 z Between CN18 (male) (1) (2) Between CN18 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN18. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC2 (female) (9) Resistance Max. 1 z (Disconnection or defective CN18 (female) (1) contact) Wiring harness between ATC2 (female) (19) Resistance Max. 1 z CN18 (female) (2) Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. fective Wiring harness between ATC2 (female) (9) Resistance 5 15 z ATC2 (female) (19) Cause
Possible causes and standard value 2 in normal state
20-522
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SDL1]
[15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code Lo clutch solenoid: *See separate list (L1) Trouble (Command is OFF and fill switch is ON) 15SDL1 TM When the output to the Lo clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Cause
1 Lo clutch fill switch defective Between CN17 (male) (1) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN17. 3) Connect T-adapter. Resistance between Wiring harness between ATC5A ATC5A (female) (10), (female) (10) CN17 (female) (1) CN17 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter.
Min. 1 Mz
HD465-7, HD605-7
20-523
(10)
TROUBLESHOOTING
[15SDMA]
[15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA)

Lo clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is E03 15SDMA TM sensed) When a signal is output to the Lo clutch ECMV, the signal from the fill switch is kept OFF and the value 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. Action of controller The controller sets the gear in Neutral. Action code Failure code Controller code
Related information If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure
control valve for a defect. Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN16. 3) Connect T-adapter. Lo clutch ECMV defective Resistance 5 15 z Between CN16 (male) (1) (2) Between CN16 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN16. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC2 (female) (7) Resistance Max. 1 z (Disconnection or defective CN16 (female) (1) contact) Wiring harness between ATC2 (female) (17) Resistance Max. 1 z CN16 (female) (2) Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. fective Wiring harness between ATC2 (female) (7) Resistance 5 15 z ATC2 (female) (17) Cause
Possible causes and standard value 2 in normal state
20-524
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SEL1]
[15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SEL1 TM
Trouble
1st clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)
When the output to the 1st clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Cause
1 1st clutch fill switch defective
When disResistance Min. 1 Mz Between CN7 (male) (1) chassis engaged ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN7. 3) Connect T-adapter. Wiring harness between ATC5A (female) (13) CN7 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Resistance between ATC5A (female) (13), CN7 (female) (1) chassis ground Min. 1 Mz
HD465-7, HD605-7
20-525
(10)
TROUBLESHOOTING
[15SEMA]
[15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SEMA TM
1st clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 1st clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft 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 1st clutch and pressure
control valve for a defect. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN6. 3) Connect T-adapter. Between CN6 (male) (1) (2) Resistance 5 15 z Between CN6 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 CN6. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (2) Resistance Max. 1 z CN6 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) Resistance Max. 1 z CN6 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
20-526
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SFL1]
[15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SFL1 TM
Trouble
2nd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)
When the output to the 2nd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Cause
2nd clutch fill switch defective
When disResistance Min. 1 Mz Between CN9 (male) (1) chassis engaged ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN9. 3) Connect T-adapter. Wiring harness between ATC5A (female) (14) CN9 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Resistance between ATC5A (female) (14), CN9 (female) (1) chassis ground Min. 1 Mz
HD465-7, HD605-7
20-527
(10)
TROUBLESHOOTING
[15SFMA]
[15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SFMA TM
2nd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 2nd clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft 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 2nd clutch and pressure
control valve for a defect. Cause Standard value in normal state/Remarks on troubleshooting
Resistance 5 15 z
Between CN8 (male)(1) , (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN8. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (4) Resistance Max. 1 z CN8 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) Resistance Max. 1 z CN8 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
20-528
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SGL1]
[15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SGL1 TM
Trouble
3rd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)
When the output to the 3rd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Cause
3rd clutch fill switch defective
Between CN13 (male) (1) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN13. 3) Connect T-adapter. Resistance between Wiring harness between ATC5A ATC5A (female) (15), (female) (15) CN13 (female) (1) CN13 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Min. 1 Mz
HD465-7, HD605-7
20-529
(10)
TROUBLESHOOTING
[15SGMA]
[15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SGMA TM
3rd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 3rd clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft 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 3rd clutch and pressure
20-530
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SHL1]
[15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SHL1 TM
Trouble
4th clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)
When the output to the 4th clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Cause
4th clutch fill switch defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN15. 3) Connect T-adapter. Wiring harness between ATC5A (female) (11) CN15 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Resistance between ATC5A (female) (11), CN15 (female) (1) chassis ground Min. 1 Mz
HD465-7, HD605-7
20-531
(10)
TROUBLESHOOTING
[15SHMA]
[15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SHMA TM
4th clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)
When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft 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 4th clutch and pressure
20-532
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[15SJL1]
[15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1)

Action code E03
Contents of trouble
Failure code Controller code 15SJL1 TM
Trouble
Lockup clutch solenoid: 15SJ (L1) (Command is OFF and fill switch is ON)
When the output to the lockup clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged. 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.
The lockup operation is reset and the gear cannot be shifted. Problem that appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
Related information This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).
Cause
Lockup clutch fill switch defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN21. 3) Connect T-adapter. Resistance between Wiring harness between ATC5A ATC5A (female) (17), (female) (17) CN21 (female) (1) CN21 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. Min. 1 Mz
HD465-7, HD605-7
20-533
(10)
TROUBLESHOOTING
[15SJMA]
[15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA)

Action code E03
Contents of trouble
Failure code Controller code 15SJMA TM
Trouble
Lockup clutch solenoid: 15SJ (MA) (Command is OFF, fill switch is ON, and slip is sensed)
When a signal is output to the lockup clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the engine 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.
The lockup operation is reset and the gear cannot be shifted. Problem that 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. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN20. 3) Connect T-adapter. Between CN20 (male) (1) (2) Resistance 5 15 z Between CN20 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A and CN20. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) Resistance Max. 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) Resistance Max. 1 z CN20 (female) (2) 3 Defective sensing by speed Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor
Lockup clutch ECMV defective
20-534
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[2F00KM]
[2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM)

Action code Not set
Contents of trouble
Failure code Controller code 2F00KM TM
Trouble
Parking brake: Mistake in operation or setting (KM) (Parking brake drags)
When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency brake 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).
Cause
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. 1) Turn the starting switch OFF. 2) Replace R03 with normal one. When the parking brake relay (R03) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R03. 3) Check the relay. Between R03 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R03. 3) Check the relay. 4) Apply voltage between R03 (male) (1) (2). Apply 24 V between Resistance Min. 1 Mz Between R03 (male) (1) (2). (3) (6) Do not apply 24 V beResistance Max. 1 z tween (1) (2). 1) Turn the starting switch OFF. 2) Disconnect connector PSW. 3) Connect T-adapter. 4) Start the engine. 3 Parking brake oil pressure switch defective Set parking brake switch in FREE posiBetween PSW (male) position. (1) (2) Set parking brake switch in PARK position. Resistance Min. 1 Mz Resistance 200 400 z Yes No Relay (R03) Relay (R03)
Parking brake relay (R03) defective
Resistance Max. 1 z
Mistake in operation of emergency brake 4 (Operation of emergency brake during travel)
Operate the emergency brake only when necessary.
HD465-7, HD605-7
20-535
(10)
TROUBLESHOOTING
[2F00KM]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R03. 3) Connect T-adapter.
Wiring harness between R03 (female) (2), (6) Resistance Max. 1 z Disconnection in wiring har- chassis ground 1) Turn the starting switch OFF. ness 5 (Disconnection or defective 2) Disconnect connectors R03, BT3, and PSW. 3) Connect T-adapter. contact) Wiring harness between fuse BT3 (16) PSW Resistance Max. 1 z (female) (1) Wiring harness between R03 (female) (1) Resistance Max. 1 z PSW (female) (2) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connectors BRC5A and R03. 3) Connect T-adapter. Between BRC5A (female), R03 (female) (3) Resistance Min. 1 Mz chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4) Connect connector BRC5A 5) Start the engine. 7 Retarder controller defective Set parking brake switch in FREE posiBetween BRC5A (5) tion. chassis ground Set parking brake switch in PARK position. Voltage Max. 1 V
Ground fault of wiring harness
Voltage
20 30 V
20-536
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[989A00]
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00)

Action code E02
Contents of trouble
Failure code Controller code 989A00 TM
Trouble Engine overrun prevention command signal: Operation (00)
When the gear speed is not in neutral, the transmission input shaft speed signal rises higher than 2,600 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 Related information This failure can be checked in the monitoring function (Code: 35000).
Cause
aIf the machine is traveling under the condition where the transmission Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2,600 rpm, the engine is and standard value overrunning. in normal state If the machine is not traveling under the condition where the transmisTransmission controller de2 sion input shaft speed signal rises higher than 2,600 rpm, the transfective mission controller is defective.
HD465-7, HD605-7
20-537
(10)
TROUBLESHOOTING
[989AKZ]
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E01
Contents of trouble
Failure code Controller code 989AKZ TM
Trouble
Engine overrun prevention command signal: Disconnection or short circuit (KZ)
There is disconnection, grounding fault, or short circuit with power source in the engine overrun prevention 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.
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and BRC5B. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ATC1 (female) (13) Resistance Max. 1 z (Disconnection or defective BRC5B (female) (5) contact) Wiring harness between fuse BT3 Voltage between ATC1 20 30 V terminal (14) ATC1 (female) (4) (4) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 BRC5B. 3) Connect T-adapter. Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (13), Min. 1 Mz male) (13) BRC5B (female) (5) BRC5B (female) (5) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 BRC5B. 3) Connect T-adapter. 3 Hot short in wiring harness Wiring harness between ATC1 (female) (13) BRC5B (female) (5) Voltage between ATC1 (female) (13), BRC5B (female) (5) chassis ground Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector BRC5B. 3) Connect T-adapter. 4 Retarder controller defective 4) Connect the connector. 5) Start the engine. Between BRC5B (5) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Connect T-adapter. 5 4) Connect the connector. fective 5) Start the engine. Between ATC1 (13) chassis ground Voltage Max. 1 V Voltage Max. 1 V
20-538
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[AA10NX]
[AA10NX] AIR CLEANER ELEMENT: CLOGGING (NX)

Action code E01
Contents of trouble
Failure code Controller code AA10NX TM
Trouble Air cleaner element: Clogging (NX)
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 Related information This failure can be checked in the monitoring function (Code: 33200).
Cause 1 Clogging of air cleaner
Standard value in normal state/Remarks on troubleshooting The dust indicator is not red. The dust indicator is red. 1) Turn the starting switch OFF. 2) Replace R32 with normal one. 3) Turn the starting switch ON. When the dust indicator relay (R32) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R32. 3) Check the relay. Between R32 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R32. 3) Check the relay. 4) Apply voltage between R32 (male) (1) (2). Apply 24 V between Resistance Min. 1 Mz Between R32 (male) (1) (2). (3) (6) Do not apply 24 V beResistance Max. 1 z tween (1) (2). Resistance 200 400 z No Yes Relay (R32) is normal. Relay (R32) is defective. Air cleaner is normal. Air cleaner is clogged.
Dust indicator relay (R32) defective
1) Turn the starting switch OFF. Possible causes 2) Disconnect connectors FR01. and standard value Air cleaner clogging sensor 3) Connect T-adapter. 3 in normal state defective Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z (1) (2) Air cleaner is clogged. Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and R32. Disconnection in wiring har- 3) Connect T-adapter. ness 4 Wiring harness between ATC3A (female) (16) (Disconnection or defective Resistance Max. 1 z R32 (female) (6) contact) Wiring harness between ATC3A (female) (19) Resistance Max. 1 z R32 (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connector R32 and FR01. 3) Connect T-adapter. Wiring harness between R32 (female) (2) FR01 (female) (1) Resistance between R32 (female) (2), FR01 (female) (1) chassis ground Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect connector. 6 fective 5) Turn the starting switch ON. Between ATC3A (19) Air cleaner is normal. (16) Air cleaner is clogged. Voltage Voltage 20 30 V Max. 1 V
HD465-7, HD605-7
20-539
(10)
TROUBLESHOOTING
[AA10NX]
20-540
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[AB00MA]
[AB00MA] ALTERNATOR: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code AB00MA TM
Trouble
Alternator: Malfunction (MA) (Failure in battery charging circuit)
A generation signal is not input from the alternator while the engine is running.
Action of controller None in particular. If the machine is used without repairing, the source voltage may lower so much that the machine cannot Problem that appears on machine travel.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector alternator terminal R. 3) Start the engine.
1 Alternator defective
Between alternator R E
Voltage
20 30 V
aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started. 1) Turn the starting switch OFF. 2) Disconnect connector ATC3B. 3) Connect T-adapter. Disconnection in wiring harPossible causes ness and standard value 2 (Disconnection or defective in normal state contact) Wiring harness between ATC3B (female) (1) alternator terminal R Voltage between ATC3B (fe20 30 V male) (1) chassis ground Resistance Max. 1 z
aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started. Wiring harness between battery relay terminal Resistance Max. 1 z M alternator terminal R
1) Turn the starting switch OFF. 2) Disconnect connector ATC3B. 3) Connect T-adapter. Transmission controller de- 4) Connect the connector. 3 5) Start the engine. fective Between ATC3B (1) chassis ground Voltage 20 30 V aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started.
HD465-7, HD605-7
20-541
(10)
TROUBLESHOOTING
[AB00MA]
20-542
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[B@BCZK]
[B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK)

Action code E01
Contents of trouble
Failure code Controller code B@BCZK TM
Trouble Lowering of radiator coolant: Lowering of level (ZK)
The radiator coolant level switch signal circuit is opened (disconnected from GND).

Problem that If the machine is used without repairing, the engine may overheat. appears on machine Related information This failure can be checked in the monitoring function (Code: 33100).
Cause 1
The radiator coolant level is normal. Lowering of radiator coolant aIf the radiator coolant level is low, check around the engine and ralevel diator for coolant leakage before adding coolant . 1) Turn the starting switch OFF. 2) Disconnect connector FL01. 3) Connect T-adapter.
Radiator coolant level switch defective
Radiator coolant level Resistance Max. 1 z Between FL01 (male) is normal. (1) (2) Radiator coolant level Resistance Min. 1 Mz is low.
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and FL01. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC5A (female) (3) Resistance Max. 1 z (Disconnection or defective FL01 (female) (1) contact) Wiring harness between FL01 (female) (2) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Insert T-adapter. 4) Connect the connector. Transmission controller de- 5) Turn the starting switch ON. 3 fective Radiator coolant level Between ATC5A (fe- is normal. male) (3) chassis Radiator coolant level ground is low.
Voltage Voltage
Max. 1 V 20 30 V
HD465-7, HD605-7
20-543
(10)
TROUBLESHOOTING
[D1B0KZ]
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code E03
Contents of trouble
Failure code Controller code D1B0KZ TM
Transmission controller cutout relay: Disconnection or short cirTrouble cuit (KZ) (Disconnection or short circuit)
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 The gear is set in Neutral suddenly during travel and the machine cannot start again. appears on machine Related information None in particular.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R15 with normal one. 3) Turn the starting switch ON. When transmission cutout relay (R15) is replaced, is failure repaired? No Yes Relay (R15) is normal. Relay (R15) is defective.
1) Turn the starting switch OFF. 2) Disconnect connector R15. Transmission controller cut- 3) Check the relay. 1 out relay (R15) defective Between R15 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R15. 3) Check the relay. 4) Apply voltage between R15 (male) (1) (2). Between R15 (male) (3) (5) Possible causes and standard value in normal state Apply 24 V between (1) (2). Do not apply voltage between (1) (2).
Resistance 200 400 z
Resistance Max. 1 z Resistance Min. 1 Mz
Disconnection in wiring harWiring harness between ATC1 (female) (14) ness Resistance Max. 1 z 2 (Disconnection or defective R15 (female) (1) contact) Between R15 (female) (2) chassis ground Resistance Max. 1 z Wiring harness between fuse BT2 Voltage between ATC1 20 30 V terminal (22) ATC1 (female) (5) (5) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and R15. 3) Connect T-adapter. Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (14), male) (14) R15 (female) (1) R15 (female) (1) chassis ground Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and R15. 3) Connect T-adapter.
1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. Transmission controller de- 4) Turn the starting switch ON. 4 fective When failure code to turn transmisBetween sion cutout relay OFF is displayed ATC1 (14) (Example: 1500LO) (8), (16) When failure code is not displayed
Voltage Voltage
Max. 1 V 20 30 V
20-544
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[D1BOKZ]
HD465-7, HD605-7
20-545
(1)
TROUBLESHOOTING
[D5ZMKZ]
[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E01
Contents of trouble
Failure code Controller code D5ZMKZ TM
Trouble
Disconnection, grounding fault, or short circuit in engine output mode command line: Disconnection or short circuit (KZ)
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).
Cause
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors ATC1 ECMB. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between ATC1 (female) (15) contact) Resistance Max. 1 z ECMB (female) (19) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ECMB. 3) Connect T-adapter. Wiring harness between Resistance between ATC1 ATC1 (female) (15) ECMB (female) (15), ECMB (feMin. 1 Mz (female) (19) male) (19) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and BRC5B. 3) Connect T-adapter. Between ATC1 (female) (15), ECMB (female) (19) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Connect T-adapter. 4) Connect the connector. 5) Start the engine. Between ECMB (19) In power mode chassis ground In economy mode 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Transmission controller de- 4) Disconnect the connector. 5 fective 5) Start the engine. Between ATC1 (15) In power mode chassis ground In economy mode Voltage Voltage 9.4 12 V 0 2.4 V Voltage Voltage 9.4 12 V 0 2.4 V Voltage Max. 1 V
3 Hot short in wiring harness Possible causes and standard value in normal state
20-546
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQ0KK]
[DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)

Action code E03
Contents of trouble
Failure code Controller code DAQ0KK TM
Trouble Transmission controller: Lowering of source/input voltage (KK)
While the engine is running, the voltages of both main power source voltage circuit and direct power source voltage circuit lower below 18 V.
Action of controller The controller sets the gear in Neutral. The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage Problem that appears on machine rises to the normal level. If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), and (17) for grounding
fault. Cause Standard value in normal state/Remarks on troubleshooting 1) Test the battery voltage and specific gravity of the battery fluid. 1 Battery defective Battery voltage Specific gravity of battery fluid 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Wiring harness between ATC1 (female) (8), (16) chassis ground Resistance Max. 1 z Voltage Specific gravity Min. 24 V Min. 1.26
1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Disconnection in wiring har- 3) Connect T-adapter. 4) Connect the connector. ness 2 (Disconnection or defective Wiring harness between battery, Voltage between ATC1 contact) battery relay terminal B, ATC1 (7) (7) (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.
20 30 V
Wiring harness between battery re- Voltage between ATC1 20 30 V lay terminal M ATC1 (9), (17) (9), (17) (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1 3) Insert T-adapter. 4) Connect the connector. 3 Between ATC1 (7) (8), (16) Transmission controller de1) Turn the starting switch OFF. fective 2) Disconnect connector ATC1 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ATC1 (9), (17) (8), (16) Voltage 20 30 V
Voltage
20 30 V
HD465-7, HD605-7
20-547
(10)
TROUBLESHOOTING
[DAQ0KK]
20-548
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQ1KK]
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code E03
Contents of trouble
Trouble
Main power line of transmission controller: Lowering of source/input voltage (KK)
The main power source voltage is lower than the direct power source voltage by 5 V or more.
Action of controller The controller prohibits updating of information about input.

Problem that The condition before the failure is kept. appears on machine Related information If the fuse is broken, check the line between the fuse ATC1 (female) (9) and (17) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Wiring harness between ATC1 (female) (8), (16) chassis ground Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness 1 (Disconnection or defective Wiring harness between battery Voltage between battery relay terminal B 20 30 V contact) battery relay terminal B chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between battery re- Voltage between ATC1 20 30 V lay terminal M ATC1 (9), (17) (9), (17) (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Insert T-adapter. 2 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC1 (9), (17) (8), (16) Voltage 20 30 V
HD465-7, HD605-7
20-549
(10)
TROUBLESHOOTING
[DAQ1KK]
20-550
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQ2KK]
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code E03
Contents of trouble
Trouble
Transmission controller load power line: Lowering of source/input voltage (KK)
While the transmission controller source voltage is normal, the solenoid source voltage is below 18 V. The controller turns the transmission cutout relay OFF. The controller sets the gear in Neutral.
Problem that The gear is set in Neutral suddenly during travel and the machine cannot start again. appears on machine Related information If the fuse is broken, check the line between the fuse and ATC1 (female) (9) and (17) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R15 with normal one. 3) Turn the starting switch ON When transmission cutout relay (R15) is replaced, is failure repaired? No Yes Relay (R15) is normal. Relay (R15) is defective.
1) Turn the starting switch OFF. 2) Disconnect connector R15. Transmission controller cut- 3) Check the relay. 1 out relay (R15) defective Between R15 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R15. 3) Check the relay. 4) Apply voltage between R15 (male) (1) (2). Between R15 (male) (3) (5) Apply 24 V between (1) (2). Do not apply voltage between (1) (2).
Resistance Max. 1 z Resistance Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors R15. 3) Insert T-adapter. 4) Connect the connector. Disconnection in wiring har- Wiring harness between fuse BT3 Voltage between R15 (female) (3) chassis ness to 14 R15 (female) (3) 2 ground (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and R15. 3) Connect T-adapter. 20 30 V
Wiring harness between ATC2 (1), (12) R15 Resistance Max. 1 z (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Insert T-adapter. 3 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC2 (1), (12) chassis ground Voltage 20 30 V
HD465-7, HD605-7
20-551
(10)
TROUBLESHOOTING
[DAQ2KK]
20-552
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQ3KK]
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code E03
Contents of trouble
Trouble
Direct line of transmission controller battery: Lowering of source/ input voltage (KK)
The direct power source voltage is below 5 V.

Problem that This failure does not have a serious effect on the machine. appears on machine Related information If the fuse is broken, check the line between the fuse and ATC1 (female) (7) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter.
Wiring harness between ATC1 (female) (8), Resistance Max. 1 z Disconnection in wiring har- (16) chassis ground ness 1 (Disconnection or defective 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. contact) Possible causes 3) Insert T-adapter. and standard value 4) Connect the connector. in normal state Wiring harness between battery, Voltage between ATC1 20 30 V battery relay terminal B, ATC1 (7) (7) (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Insert T-adapter. 2 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC1 (7) (8), (16) Voltage 20 30 V
HD465-7, HD605-7
20-553
(10)
TROUBLESHOOTING
[DAQ9KM]
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM)

Action code E03 Failure code Controller code DAQ9KM TM Trouble Transmission controller wiring harness: Mistake in operation or 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. The controller turns the transmission cutout relay OFF. Action of controller The controller keeps the gear speed in neutral. This failure is not recorded in the fault history.
Problem that When the starting operation is performed, the machine does not start. appears on machine Related information None in particular.
Cause 1 Wrong connection of connector
Standard value in normal state/Remarks on troubleshooting The connector of the connector check signal is connected normally. aConnector check signal connector: ATC3A (1) (OPEN), ATC5A (1) (CLOSE)
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector ATC5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between ATC5A (female) (1) contact) Resistance Max. 1 z chassis ground Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connector ATC3A. 3) Connect T-adapter. Wiring harness between ATC3A (female) (1) chassis ground Resistance between ATC3A (female) (1) chassis ground Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC5A (female) (1) Resistance Max. 1 z chassis ground Between ATC3A (female) (1) chassis ground Resistance Min. 1 Mz
20-554
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQ9KQ]
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)
Action code E03
Contents of trouble
Failure code Controller code DAQ9KQ TM
Trouble
Transmission controller wiring harness: Disagreement of model selection signals (KQ)
The model selection signal input when the starting switch is turned ON is different from the setting of the controller.
The controller turns the transmission cutout relay OFF. Action of controller The controller sets the gear speed in neutral. This failure is not recorded in the fault history.
Problem that When the starting operation is performed, the machine does not start. appears on machine Related information This failure can be checked in the monitoring function (Code: 02701, 02702, 02703).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ATC5A (female) (14) Resistance Max. 1 z (Disconnection or defective chassis ground contact) Wiring harness between ATC5A (female) (16) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Connect T-adapter. Wiring harness between ATC5A (female) (15) MS21 (female) Resistance between ATC5A (female) (15), Min. 1 Mz MS21 (female) chassis ground
Possible causes Ground fault in wiring harand standard value 2 ness in normal state
Wrong setting of rotary switch
For setting of the rotary switch, see ADJUSTING TRANSMISSION CONTROLLER. 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Connect T-adapter. Between ATC5A (female) (14) chassis ground Resistance Max. 1 z Between ATC5A (female) (15) chassis ground Resistance Min. 1 Mz Between ATC5A (female) (16) chassis ground Resistance Max. 1 z
Wrong setting of rotary switch
HD465-7, HD605-7
20-555
(10)
TROUBLESHOOTING
[DAQAKQ], [DAQSMA]
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)
Action code E03
Contents of trouble
Failure code Controller code DAQAKQ TM
Trouble
Transmission controller wiring harness: Disagreement of model selection signals (KQ)
Setting of the model by the rotary switch does not agree with setting in the controller.
The controller turns the transmission cutout relay OFF. Action of controller The controller sets the gear speed in neutral. This failure is not recorded in the fault history.
Problem that When the starting operation is performed, the machine does not start. appears on machine Related information This failure can be checked in the monitoring function (Code: 30801).
Cause
Wrong setting of rotary For setting of the rotary switch, see ADJUSTING TRANSMISSION Possible causes 1 switch CONTROLLER. and standard value For setting of the rotary switch, see ADJUSTING TRANSMISSION in normal state Transmission controller de2 CONTROLLER. fective aIf setting is normal, the transmission controller is defective.
[DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA)

Action code E03
Contents of trouble
Failure code Controller code DAQSMA TM
Trouble Transmission controller: Malfunction (MA)
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 When the starting operation is performed, the machine does not start. appears on machine
If failure code "DAQSKR" of the machine monitor system is indicated, perform troubleshooting for it first. Related information Do not turn the starting switch to the left before starting the engine (Since the engine preheating system is automatic, the starting switch does not need to be turned to the left). Cause Standard value in normal state/Remarks on troubleshooting
Possible causes aIf the failure is not repaired by replacing the transmission controller, 1 Machine monitor defective and standard value the machine monitor is defective. in normal state Transmission controller de- aIf the failure is repaired by replacing the transmission controller, the 2 fective transmission controller is defective.
20-556
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDTGKA]
[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTGKA TM
Lockup clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the lockup clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral. 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.
Cause
Lockup clutch fill switch defective
1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (17) contact) Resistance Max. 1 z CN21 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3 Transmission controller defective When disResistance Min. 1 Mz Between ATC5A (female) (17) engaged chassis ground When enResistance Max. 1 z gaged
HD465-7, HD605-7
20-557
(10)
TROUBLESHOOTING
[DDTHKA]
[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTHKA TM
Hi clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that The gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information This failure can be checked in the monitoring function (Code: 31511, 31600, 31610).
Cause
1 Hi clutch fill switch defective Between CN19 (male) (1) chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact)
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN19. 3) Connect T-adapter. Wiring harness between ATC5A (female) (12) Resistance Max. 1 z CN19 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter.
20-558
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDTJKA]
[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTJKA TM
Lo clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that The gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information This failure can be checked in the monitoring function (Code: 31510, 31601, 31611).
Cause
1 Lo clutch fill switch defective Between CN17 (male) (1) chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact)
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN17. 3) Connect T-adapter. Wiring harness between ATC5A (female) (10) Resistance Max. 1 z CN17 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter.
HD465-7, HD605-7
20-559
(10)
TROUBLESHOOTING
[DDTKKA]
[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTKKA TM
1st clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
The gear cannot be shifted. Problem that appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
Cause
1 1st clutch fill switch defective
When disResistance Min. 1 Mz Between CN7 (male) (1) chassis engaged ground When enResistance Max. 1 z gaged
20-560
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDTLKA]
[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTLKA TM
2nd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Cause
2nd clutch fill switch defective
When disResistance Min. 1 Mz Between CN9 (male) (1) chassis engaged ground When enResistance Max. 1 z gaged
HD465-7, HD605-7
20-561
(10)
TROUBLESHOOTING
[DDTMKA]
[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTMKA TM
3rd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Cause
3rd clutch fill switch defective
20-562
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDTNKA]
[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTNKA TM
R clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Cause
1 R clutch fill switch defective Between CN11 (male) (1) chassis ground
HD465-7, HD605-7
20-563
(10)
TROUBLESHOOTING
[DDTPKA]
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DDTPKA TM
4th clutch fill switch : Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Cause
4th clutch fill switch defective
20-564
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DF10KA]
[DF10KA] SHIFT LEVER: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DF10KA TM
Trouble Shift lever: Disconnection (KA)
The shift lever signal is not input at all. The gear may be shifted up above the gear speed set with the shift lever.
Action of controller The controller keeps the condition before occurrence of the failure..
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.

Related information None in particular.
Cause 1 Wrong operation
Standard value in normal state/Remarks on troubleshooting The shift lever is pressed by some force while it is not operated. The shift lever is stopped between 2 positions. 1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Connect T-adapter. Wiring harness between BT3 (10) SF1 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Insert T-adapter. Wiring harness between ATC5B (female) (2) Resistance Max. 1 z SF1 (female) (3) Resistance Max. 1 z
Wiring harness between ATC5B (female) (3) Resistance Max. 1 z Disconnection in wiring har- SF1 (female) (4) ness Wiring harness between ATC5B (female) (4) Resistance Max. 1 z 2 (Disconnection or defective SF1 (female) (5) contact of connector) Wiring harness between ATC5B (female) (5) Resistance Max. 1 z SF1 (female) (6) Possible causes and standard value in normal state Wiring harness between ATC5B (female) (6) Resistance Max. 1 z SF1 (female) (7) Wiring harness between ATC5B (female) (7) Resistance Max. 1 z SF1 (female) (8) Wiring harness between ATC5B (female) (8) Resistance Max. 1 z SF1 (female) (9) Wiring harness between ATC5B (female) (9) Resistance Max. 1 z SF1 (female) (10) Wiring harness between ATC5B (female) (10) Resistance Max. 1 z SF1 (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Connect T-adapter. Wiring harness between ATC5B (female) (2) SF1 (female) (3) 3 Hot short in wiring harness Wiring harness between ATC5B (female) (3) SF1 (female) (4) Resistance between ATC5B (female) (2), SF1 (female) (3) chassis ground Resistance between ATC5B (female) (3), SF1 (female) (4) chassis ground Resistance between ATC5B (female) (4), SF1 (female) (5) chassis ground Min. 1 Mz
Min. 1 Mz
Wiring harness between ATC5B (female) (4) SF1 (female) (5)
Min. 1 Mz
HD465-7, HD605-7
20-565
(10)
TROUBLESHOOTING
[DF10KA]
Cause
Standard value in normal state/Remarks on troubleshooting Wiring harness between ATC5B (female) (5) SF1 (female) (6) Resistance between ATC5B (female) (5), SF1 (female) (6) chassis ground Resistance between ATC5B (female) (6), SF1 (female) (7) chassis ground Resistance between ATC5B (female) (7), SF1 (female) (8) chassis ground Resistance between ATC5B (female) (8), SF1 (female) (9) chassis ground Resistance between ATC5B (female) (9), SF1 (female) (10) chassis ground Resistance between ATC5B (female) (10), SF1 (female) (11) chassis ground Min. 1 Mz
Min. 1 Mz
Wiring harness between ATC5B (female) (7) SF1 (female) (8) 3 Hot short in wiring harness Wiring harness between ATC5B (female) (8) SF1 (female) (9)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Wiring harness between ATC5B (female) (10) SF1 (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between SF1 (3) chassis ground Between SF1 (4) chassis ground Between SF1 (5) chassis ground Between SF1 (6) chassis ground Between SF1 (7) chassis ground Between SF1 (8) chassis ground Between SF1 (9) chassis ground Between SF1 (10) chassis ground Between SF1 (11) chassis ground
Min. 1 Mz
When shift range is "R" When shift range is not "R" When shift range is "N" When shift range is not "N" When shift range is "D" When shift range is not "D" When shift range is "6" When shift range is not "6" When shift range is "5" When shift range is not "5" When shift range is "4" When shift range is not "4" When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2" When shift range is "1" When shift range is not "1"
Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage
20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V
4 Gearshift lever defective
20-566
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DF10KA]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When shift range is "R" Between ATC5B (2) When shift range is not chassis ground "R" When shift range is "N" Between ATC5B (3) When shift range is not chassis ground "N" When shift range is "D" Between ATC5B (4) When shift range is not chassis ground "D" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 z 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V
When shift range is "6" Possible causes Between ATC5B (5) When shift range is not and standard value Transmission controller de- chassis ground 5 "6" in normal state fective When shift range is "5" Between ATC5B (6) When shift range is not chassis ground "5" When shift range is "4" Between ATC5B (7) When shift range is not chassis ground "4" When shift range is "3" Between ATC5B (8) When shift range is not chassis ground "3" When shift range is "2" Between ATC5B (9) When shift range is not chassis ground "2" When shift range is "1" Between ATC5B (10) When shift range is not chassis ground "1"
HD465-7, HD605-7
20-567
(10)
TROUBLESHOOTING
[DF10KA]
20-568
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DF10KB]
[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB)

Action code E03
Contents of trouble
Failure code Controller code DF10KB TM
Trouble Shift lever: Short circuit (KB)
The shift lever signals are input from 2 or more systems.
The controller controls with the signal having higher priority. (1): N > D > 6 > 5 > 4 > 3 > 2 > 1. Action of controller (2): N > R If the signals of systems (1) and (2) are input simultaneously, the controller sets the gear in neutral.
Problem that The gear is kept in neutral and the machine cannot start. appears on machine Related information None in particular.
The gear may be shifted up above the gear speed set with the shift lever. The shift lever position lamp is different from the shift lever position.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Insert T-adapter. Wiring harness between ATC5B (female) (2) SF1 (female) (3) Voltage between ATC5B (female) (2), SF1 (female) (3) chassis ground Voltage between ATC5B (female) (3), SF1 (female) (4) chassis ground Voltage between ATC5B (female) (4), SF1 (female) (5) chassis ground Voltage between ATC5B (female) (5), SF1 (female) (6) chassis ground Voltage between ATC5B (female) (6), SF1 (female) (7) chassis ground Voltage between ATC5B (female) (7), SF1 (female) (8) chassis ground Voltage between ATC5B (female) (8), SF1 (female) (9) chassis ground Voltage between ATC5B (female) (9), SF1 (female) (10) chassis ground Voltage between ATC5B (female) (10), SF1 (female) (11) chassis ground
Max. 1 V
Max. 1 V
Max. 1 V
Possible causes Short circuit in wiring harand standard value 1 ness in normal state (Hot short in wiring harness) Wiring harness between ATC5B (female) (6) SF1 (female) (7)
Max. 1 V
Max. 1 V
Max. 1 V
Max. 1 V
Max. 1 V
Max. 1 V
HD465-7, HD605-7
20-569
(10)
TROUBLESHOOTING
[DF10KB]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between SF1 (3) chassis ground Between SF1 (4) chassis ground Between SF1 (5) chassis ground When shift range is "R" When shift range is not "R" When shift range is "N" When shift range is not "N" When shift range is "D" When shift range is not "D" When shift range is "6" When shift range is not "6" When shift range is "5" When shift range is not "5" When shift range is "4" When shift range is not "4" When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2" When shift range is "1" When shift range is not "1" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 z 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V
2 Gearshift lever defective
Between SF1 (6) chassis ground Between SF1 (7) chassis ground Between SF1 (8) chassis ground
Between SF1 (9) chassis ground Between SF1 (10) chassis ground Between SF1 (11) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When the right FNR switch is installed (Turn the right FNR switch ON) When shift range is "R" Between ATC5B (2) When shift range is not chassis ground "R" When shift range is "N" Transmission controller de- Between ATC5B (3) When shift range is not 3 chassis ground fective "N" When shift range is "D" Between ATC5B (4) When shift range is not chassis ground "D" Between ATC5B (5) When shift range is "6" chassis ground When shift range is not "6" When shift range is "5" Between ATC5B (6) When shift range is not chassis ground "5" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 z 20 30 V Max. 1 V
20-570
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DF10KB]
Cause
Standard value in normal state/Remarks on troubleshooting When shift range is "4" Between ATC5B (7) When shift range is not chassis ground "4" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V 20 30 V Max. 1 V
Between ATC5B (8) chassis ground Possible causes Transmission controller deand standard value 3 fective in normal state Between ATC5B (9) chassis ground
When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2"
When shift range is "1" Between ATC5B (10) When shift range is not chassis ground "1"
HD465-7, HD605-7
20-571
(10)
TROUBLESHOOTING
[DGF1KX]
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DGF1KX TM Trouble Transmission valve oil temperature sensor: Out of input signal range (KX)
The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0.97 V (above Contents of trouble 150C) 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
This failure can be checked in the monitoring function (Code: 32500).

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". Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN24. 3) Connect T-adapter. Between CN24 (male) Oil temperature: 25C Resistance 37 50 kz (1) (2) Oil temperature: 100C Resistance 3.5 4.0 kz
Transmission oil temperature sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and CN24. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between ATC3B (female) (9) Resistance Max. 1 z (Disconnection or defective CN24 (female) (2) contact) Wiring harness between ATC3A (female) (16) Resistance Max. 1 z CN24 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN24. 3) Connect T-adapter. Wiring harness between ATC3B (female) (9) CN24 (female) (2) Resistance between ATC3B (female) (9), CN24 (female) (2) chassis ground Min. 1 Mz
Ground fault in wiring har3 Possible causes ness and standard value in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN24. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (9) CN24 (female) (2) Voltage between ATC3B (female) (9), CN24 (female) (2) chassis ground
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and ATC3B. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 5) Turn the starting switch ON. fective Between ATC3B (fe- Oil temperature: 25C Resistance 37 50 kz male) (9) ATC3A (feOil temperature: 100C Resistance 3.5 4.0 kz male) (16)
20-572
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[GDF1KX]
HD465-7, HD605-7
20-573
(1)
TROUBLESHOOTING
[DGT1KX]
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUTSIGNAL RANGE (KX)
Action code E01
Contents of trouble
Failure code Controller code DGT1KX TM
Trouble
Torque converter oil temperature sensor: Out of input signal range (KX)
The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above 150C) 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 Related information This failure can be checked in the monitoring function (Code: 30100).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector CN23. Torque converter oil temper- 3) Connect T-adapter. 1 ature sensor defective Between CN23 (T/C-T) Oil temperature: 25C Resistance 37 50 kz (male) (1) (2) Oil temperature: 100C Resistance 3.5 4.0 kz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and CN23. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC3B (female) (7) 2 (Disconnection or defective Resistance Max. 1 z TC-SE (female) (2) contact) Wiring harness between ATC3A (female) (16) Resistance Max. 1 z CN23 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN23. 3) Connect T-adapter. Wiring harness between ATC3B (female) (7) CN23 (female) (2) Resistance between ATC3B (female) (7), CN23 (female) (2) chassis ground Min. 1 Mz
Ground fault in wiring harPossible causes 3 ness and standard value in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN23. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (7) CN23 (female) (2) Voltage between ATC3B (female) (7), CN23 (female) (2) chassis ground Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and ATC3B. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 5) Turn the starting switch ON. fective Between ATC3B (fe- Oil temperature: 25C Resistance 37 50 kz male) (7) ATC3A (feOil temperature: 100C Resistance 3.5 4.0 kz male) (16)
20-574
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHT5KX]
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)
Action code E01 Failure code Controller code DHT5KX TM Trouble Torque converter oil pressure sensor: Out of input signal range (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 Related information This failure can be checked in the monitoring function (Code: 32600).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1, ATC3A and CN22. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between ATC3A (female) (7) Resistance Max. 1 z ness CN22 (female) (C) 1 (Disconnection or defective Wiring harness between ATC3A (female) (17) contact) Resistance Max. 1 z CN22 (female) (A) Wiring harness between ATC1 (female) (3) CN22 (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN22. 3) Connect T-adapter. Wiring harness between ATC3A (female) (7) CN22 (female) (C) Resistance between ATC3A (female) (7), CN22 (female) (C) chassis ground Min. 1 Mz Resistance Max. 1 z
Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (3), CN22 (female) (B) male) (3) CN22 (female) (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN22. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (7) CN22 (female) (C) 1) Turn the starting switch OFF. 2) Disconnect connector CN22. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between CN22 (B) (A) Between CN22 (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 fective 5) Turn the starting switch ON. Between ATC1 (3) ATC3A (17) Between ATC3A (7) (17) Voltage Voltage Voltage Voltage Voltage between ATC3A (female) (7), CN22 (female) (C) chassis ground
Min. 1 Mz
0.8 2.0 V
Torque converter oil pressure sensor defective
20 30 V 0.8 2.0 V
20 30 V 0.8 2.0 V
HD465-7, HD605-7
20-575
(10)
TROUBLESHOOTING
[DHT5KX]
20-576
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DHT5L6]
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE SEPARATE LIST (L6)
Action code E01
Contents of trouble
Failure code Controller code DHT5L6 TM
Trouble Torque converter oil pressure sensor: *See separate list (L6)
While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter 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 Related information This failure can be checked in the monitoring function (Code: 32600).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN22. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (7) CN22 (female) (C) 1) Turn the starting switch OFF. 2) Disconnect connector CN22. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between CN22 (B) (A) Between CN22 (C) (A) Voltage Voltage 20 30 V 0.8 2.0 V Voltage between ATC3A (female) (7), CN22 (female) (C) chassis ground
Max. 1.2 V
Possible causes and standard value Torque converter oil presin normal state 2 sure sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 3 fective 5) Turn the starting switch ON. Between ATC1 (3) ATC3A (17) Between ATC3A (7) (17) Voltage Voltage 20 30 V 0.8 2.0 V
HD465-7, HD605-7
20-577
(10)
TROUBLESHOOTING
[DJF1KA]
[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA)

Action code E01
Contents of trouble
Failure code Controller code DJF1KA TM
Trouble Fuel level sensor: Disconnection (KA)
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 Related information This failure can be checked in the monitoring function (Code: 04201).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T01. 3) Connect T-adapter. Fuel level: When FULL Between T01 (female) (1) (2) Fuel level: When EMPTY Resistance Max. 12 z Resistance 74 100 z
1 Fuel level sensor defective
Disconnection in wiring harness 2 (Disconnection or defective contact)
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and T01. 3) Connect T-adapter. Wiring harness between ATC3B (female) (4) Resistance Max. 1 z T01 (female) (1) Wiring harness between ATC3A (female) (16) Resistance Max. 1 z T01 (female) (2)
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and T01. 3) Insert T-adapter. 4) Turn the starting switch ON.. Wiring harness between ATC3B (female) (4) T01 (female) (1) Voltage between ATC3B (female) (4), T01 (female) (1) chassis ground
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 4) Connect the connector. Transmission controller de- 5) Turn the starting switch ON. 4 fective Between ATC3B Fuel level: When FULL (female) (3) ATC3A (female) Fuel level: When EMPTY (16)
Resistance Max. 12 z Resistance 74 100 z
20-578
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK11KX]
[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code E03
Contents of trouble
Failure code Controller code DK11KX TM
Trouble Throttle angle sensor: Out of input signal range (KX)
The voltage of the signal circuit of the acceleration sensor for transmission control is below 0.6 V or 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. Related information This failure can be checked in the monitoring function (Code: 31701).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and AS2. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between ATC3B (female) (11) Resistance Max. 1 z ness AS2 (female) (2) 1 (Disconnection or defective Wiring harness between ATC3A (female) (16) contact) Resistance Max. 1 z AS2 (female) (3) Wiring harness between ATC3A (female) (6) Resistance Max. 1 z AS2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and AS2. 3) Connect T-adapter. Wiring harness between ATC3A (female) (6) AS2 (female) (1) Resistance between ATC3A (female) (6), AS2 (female) (1) chassis ground Resistance between ATC3B (female) (11), AS2 (female) (2) chassis ground Min. 1 Mz
Wiring harness between ATC3B (female) (11) AS2 (female) (2) Possible causes and standard value in normal state
Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and AS2. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (11) AS2 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector AS2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between AS2 (1) (3) Between AS2 (2) (3) Voltage Voltage 4.6 5.4 V 1.0 4.0 V Voltage between ATC3B (female) (11), AS2 (female) (2) chassis ground
Max. 1 V
Acceleration sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 fective 5) Turn the starting switch ON. Between ATC3A (6) (16) Between ATC3B (11) ATC3A (16) Voltage Voltage 4.6 5.4 V 1.0 4.0 V
HD465-7, HD605-7
20-579
(10)
TROUBLESHOOTING
[DK11KX]
20-580
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DLE2KA]
[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DLE2KA TM
Trouble Engine speed sensor: Disconnection (KA)
The signal circuit of the engine speed sensor is disconnected and signals are not input. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral. 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).
Cause Wrong adjustment of engine 1 speed sensor
Standard value in normal state/Remarks on troubleshooting Press the sensor lightly against the flywheel ring gear, and then return it by 1/2 3/4 turns. a For details, see TESTING AND ADJUSTING, "Adjustment of engine speed sensor".
1) Turn the starting switch OFF. 2) Disconnect connector E03. Engine speed sensor defec- 3) Connect T-adapter. 2 tive Between E03 (male) (1) (2) Possible causes and standard value in normal state
Resistance 500 1,000 z
Between E03 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A E03. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (13) Resistance Max. 1 z (Disconnection or defective E03 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z E03 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (13) (14)
HD465-7, HD605-7
20-581
(10)
TROUBLESHOOTING
[DLE2LC]
[DLE2LC] ENGINE SPEED SENSOR: *SEE SEPARATE LIST (LC)

Action code E01
Contents of trouble
Failure code Controller code DLE2LC TM
Trouble Engine speed sensor: *See separate list (LC)
When the engine speed sensor signal is below 350 rpm, the input transmission input shaft speed sensor signal is above 500 rpm. The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that The gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information This failure can be checked in the monitoring function (Code: 01001).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector E03. Engine speed sensor defec- 3) Connect T-adapter. 1 tive Between E03 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and E03. 3) Connect T-adapter. Wiring harness between ATC3A (female) (13) E03 (female) (1)
Between E03 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Resistance between ATC3A (female) (13), E03 (female) (1) chassis ground
Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and E03. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (13) E03 (female) (1) Voltage between ATC3A (female) (13), E03 (female) (1) chassis ground Max. 1 V
1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (13) (14)
20-582
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF1KA]
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DLF1KA TM
Trouble Transmission input shaft speed sensor: Disconnection (KA)
The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not input. 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 system 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. Related information This failure can be checked in the monitoring function (Code: 31200).
Cause Wrong adjustment of trans1 mission input shaft speed sensor
Standard value in normal state/Remarks on troubleshooting Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 1 turn. a For details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor". 1) Turn the starting switch OFF. 2) Disconnect connector CN3. 3) Connect T-adapter. Between CN3 (male) (1) (2) Resistance 500 1,000 z Between CN3 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Transmission input shaft speed sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN3. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (2) Resistance Max. 1 z (Disconnection or defective CN3 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z CN3 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (2) (14)
HD465-7, HD605-7
20-583
(10)
TROUBLESHOOTING
[DLF1LC]
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)
Action code E03
Contents of trouble
Failure code Controller code DLF1LC TM
Trouble Transmission input shaft speed sensor: *See separate list (LC)
The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sensor signal, and transmission output shaft speed sensor signal is different from the signal speed of the transmission input shaft speed sensor. 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.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN3. 3) Connect T-adapter. Between CN3 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN3. 3) Connect T-adapter. Wiring harness between ATC3A (female) (2) CN3 (female) (1) Resistance between ATC3A (female) (2), CN3 (female) (1) chassis ground Min. 1 Mz Resistance 500 1,000 z Between CN3 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Transmission input shaft speed sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN3. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (2) CN3 (female) (1) Voltage between ATC3A (female) (2), CN3 (female) (1) chassis ground
Max. 1 V
20-584
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF2KA]
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA)

Action code E03 Failure code Controller code DLF2KA TM Trouble Transmission intermediate shaft speed sensor: Disconnection (KA)
The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are Contents of trouble not input. Action of controller The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Cause
Press the sensor lightly against the revolution pickup gear, and then Wrong adjustment of transreturn it by 1/2 1 turn. 1 mission intermediate shaft a For details, see TESTING AND ADJUSTING, "Adjustment of transspeed sensor mission speed sensor". 1) Turn the starting switch OFF. Transmission intermediate 2) Disconnect connector CN4. 2 shaft speed sensor defective 3) Connect T-adapter. Between CN4 (male) (1) (2) Possible causes and standard value in normal state
Between CN4 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A CN4. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (12) (Disconnection or defective Resistance Max. 1 z CN4 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z CN4 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (12) (14) Resistance 500 1,000 z
HD465-7, HD605-7
20-585
(10)
TROUBLESHOOTING
[DLF2LC]
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)
Action code E03 Failure code Controller code DLF2LC TM Trouble Transmission intermediate shaft speed sensor: *See separate list (LC)
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sigContents of trouble nal, and transmission output shaft speed sensor signal is different from the signal speed of the transmission intermediate shaft speed sensor. Action of controller The controller keeps the current gear speed. If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that The gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information This failure can be checked in the monitoring function (Code: 31300).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN4. 3) Connect T-adapter. Between CN4 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A CN4. 3) Connect T-adapter. Wiring harness between ATC3A (female) (12) CN4 (female) (1) Resistance between ATC3A (female) (12), CN4 (female) (1) chassis ground Min. 1 Mz Resistance 500 1,000 z Between CN4 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Transmission intermediate shaft speed sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN4. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (12) CN4 (female) (1) Voltage between ATC3A (female) (12), CN4 (female) (1) chassis ground
Max. 1 V
20-586
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DLT3KA]
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DLT3KA TM
Trouble Transmission output shaft speed sensor: Disconnection (KA)
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input. 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 system is reset and the gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the gear is set in neutral Related information This failure can be checked in the monitoring function (Code: 31400).
Cause Wrong adjustment of trans1 mission output shaft speed sensor
Standard value in normal state/Remarks on troubleshooting Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 - 1 turn. a For details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor". 1) Turn the starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) (2) Resistance 500 1,000 z Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Transmission output shaft speed sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (3) Resistance Max. 1 z (Disconnection or defective CN5 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z CN5 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (3) (14)
HD465-7, HD605-7
20-587
(10)
TROUBLESHOOTING
[DLT3LC]
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)
Action code E03
Contents of trouble
Failure code Controller code DLT3LC TM
Trouble Transmission output shaft speed sensor: *See separate list (LC)
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of the transmission output shaft speed sensor. 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 gear cannot be shifted. appears on machine If the shift lever is set in the "N" position, the gear is set in neutral. Related information This failure can be checked in the monitoring function (Code: 31400).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) (2) Resistance 500 1,000 z Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, and CN5. 3) Connect T-adapter. ATC3A (female) (3), Wiring harness between ATC3A BRC3A (female) (13), (female) (3) BRC3A (female) (13) Min. 1 Mz CN5 (female) (1) CN5 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, CN5. 3) Connect T-adapter. 4) Turn the starting switch ON.
Voltage between ATC3A (female) (3), Wiring harness between ATC3A (female) (3) BRC3A (female) (13) BRC3A (female) (13), CN5 (female) (1) CN5 (female) (female) (1) chassis ground
Max. 1 V
20-588
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DLT3KA]
HD465-7, HD605-7
20-589
(1)
TROUBLESHOOTING
[DXH1KA]
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DXH1KA TM
Trouble
Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA)
When a signal is output to the lockup clutch ECMV, any current does not flow.
Action of controller The controller turns the lockup operation OFF.

Problem that The lockup system does not operate. appears on machine Related information This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)
Cause
1) Turn the starting switch OFF. 2) Disconnect connector CN20. Lockup clutch ECMV defec- 3) Connect T-adapter. 1 tive Between CN20 (male) (1) (2)
Resistance 5 15 z
Between CN20 (male) (1), (2) chassis Resistance Min. 1 Mz ground Possible causes Disconnection in wiring harand standard value ness in normal state 2 (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN20. 3) Connect T-adapter. Wiring harness between ATC2 (female) (10) Resistance Max. 1 z CN20 (female) (1) Wiring harness between ATC2 (female) (20) Resistance Max. 1 z CN20 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (10) Resistance 5 15 z ATC2 (female) (20)
20-590
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH1KB]
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH1KB TM Trouble Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB)
When a signal is output to the lockup clutch ECMV, an abnormally large current flows, or some current Contents of trouble is flowing while the signal is OFF. Action of controller 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. The lockup system is reset and the gear cannot be shifted. cannot start again, depending on the failure condition.)
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 Related information This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)
Cause
1) Turn the starting switch OFF. 2) Disconnect connector CN20. Lockup clutch ECMV defec- 3) Connect T-adapter. 1 tive Between CN20 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN10. 3) Connect T-adapter. Possible causes and standard value Short circuit in wiring har2 in normal state ness
Resistance 5 15 z
Between CN20 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Resistance between Wiring harness between ATC2 (fe- ATC2 (female) (10), male) (10) CN20 (female) (1) CN20 (female) (1) chassis ground
Min. 1 Mz
Wiring harness between ATC2 (female) (10) CN20 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (20) CN20 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (10) Resistance 5 15 z ATC2 (female) (20)
HD465-7, HD605-7
20-591
(10)
TROUBLESHOOTING
[DXH2KA]
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA)
When a signal is output to the Hi clutch ECMV, any current does not flow.

Problem that The gear is set in neutral during travel. appears on machine The machine cannot start again until it is stopped. Related information This failure can be checked in the monitoring function (Code: 31511, 31600, 31610)
Cause
Between CN18 (male) (1) (2)
Resistance 5 15 z
Between CN18 (male) (1), (2) chassis Resistance Min. 1 Mz ground Possible causes Disconnection in wiring harand standard value ness in normal state 2 (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN18. 3) Connect T-adapter. Wiring harness between ATC2 (female) (9) Resistance Max. 1 z CN18 (female) (1) Wiring harness between ATC2 (female) (19) Resistance Max. 1 z CN18 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (9) Resistance 5 15 z ATC2 (female) (19)
20-592
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH2KB]
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH2KB TM Trouble Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB)
When a signal is output to the Hi clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Problem that The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure appears on machine
The gear is set in Neutral during travel. condition.)
Related information This failure can be checked in the monitoring function (Code: 31511, 31600, 31610)
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN18. 3) Connect T-adapter. Between CN18 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN18. 3) Connect T-adapter. Resistance 5 15 z Between CN18 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Possible causes and standard value Short circuit in wiring har2 in normal state ness
Min. 1 Mz
Wiring harness between ATC2 (female) (9) CN18 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (19) CN18 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (9) ATC2 (female) (19)
Resistance 5 15 z
HD465-7, HD605-7
20-593
(10)
TROUBLESHOOTING
[DXH2KB]
20-594
(7)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH3KA]
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA)
When a signal is output to the Lo clutch ECMV, any current does not flow.

Problem that The gear is set in Neutral during travel. appears on machine The machine cannot start again until it is stopped. Related information This failure can be checked in the monitoring function (Code: 31510, 31601, 31611)
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN16. 3) Connect T-adapter. Between CN16 (male) (1) (2) Resistance 5 15 z Between CN16 (male) (1), (2) chassis ground Resistance Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN16. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (7) in normal state (Disconnection or defective Resistance Max. 1 z CN16 (female) (1) contact) Wiring harness between ATC2 (female) (17) Resistance Max. 1 z CN16 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (7) ATC2 (female) (17)
Resistance 5 15 z
HD465-7, HD605-7
20-595
(10)
TROUBLESHOOTING
[DXH3KB]
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH3KB TM Trouble Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB)
When a signal is output to the Lo clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Problem that The machine cannot start until it is stopped. appears on machine
The gear is set in Neutral during travel.
(The machine cannot start again, depending on the failure condition.)
Cause
Min. 1 Mz
Resistance 5 15 z
20-596
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH3KB]
HD465-7, HD605-7
20-597
(7)
TROUBLESHOOTING
[DXH4KA]
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA)
When a signal is output to the 1st clutch ECMV, any current does not flow.

Cause
Resistance 5 15 z
20-598
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH4KB]
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH4KB TM Trouble Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB)
When a signal is output to the 1st clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Cause
Min. 1 Mz
Resistance 5 15 z
HD465-7, HD605-7
20-599
(10)
TROUBLESHOOTING
[DXH5KA]
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA)
When a signal is output to the 2nd clutch ECMV, any current does not flow.

Cause
Resistance 5 15 z
Between CN8 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 CN8. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (4) in normal state (Disconnection or defective Resistance Max. 1 z CN8 (female) (1) contact) Wiring harness between ATC2 (female) (15) Resistance Max. 1 z CN8 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (4) ATC2 (female) (15)
Resistance 5 15 z
20-600
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH5KB]
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH5KB TM Trouble Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB)
When a signal is output to the 2nd clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Cause
1) Turn the starting switch OFF. 2) Disconnect connector CN8. 1 2nd clutch ECMV defective 3) Connect T-adapter. Between CN8 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN8. 3) Connect T-adapter. Possible causes and standard value Short circuit in wiring har2 in normal state ness
Resistance 5 15 z
Between CN8 (male) (1), (2) chassis ground Resistance Min. 1 Mz
Min. 1 Mz
Resistance 5 15 z
HD465-7, HD605-7
20-601
(10)
TROUBLESHOOTING
[DXH6KA]
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA)
When a signal is output to the 3rd clutch ECMV, any current does not flow.

Cause
1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 CN12. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (8) in normal state (Disconnection or defective Resistance Max. 1 z CN12 (female) (1) contact) Wiring harness between ATC2 (female) (18) Resistance Max. 1 z CN12 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (8) ATC2 (female) (18)
Resistance 5 15 z
20-602
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH6KB]
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH6KB TM Trouble Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB)
When a signal is output to the 3rd clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Problem that The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure appears on machine
The gear is set in Neutral during travel. condition.)
Cause
Min. 1 Mz
Resistance 5 15 z
HD465-7, HD605-7
20-603
(10)
TROUBLESHOOTING
[DXH7KA]
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Trouble
Disconnection in output circuit of R clutch solenoid: Disconnection (KA)
When a signal is output to the R clutch ECMV, any current does not flow.

Cause
Resistance 5 15 z
20-604
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXH7KB]
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXH7KB TM Trouble Short circuit in output circuit of R clutch solenoid: Short circuit (KB)
When a signal is output to the R clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Cause
Min. 1 Mz
Resistance 5 15 z
HD465-7, HD605-7
20-605
(10)
TROUBLESHOOTING
[DXHHKA]
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code DXHHKA TM
Trouble
Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA)
When a signal is output to the 4th clutch ECMV, any current does not flow.

Cause
Resistance 5 15 z
20-606
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DXHHKB]
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DXHHKB TM Trouble Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB)
When a signal is output to the 4th clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller The controller sets the gear in Neutral.
Cause
Min. 1 Mz
Wiring harness between ATC2 (female) (3) CN14 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (13) CN14 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (3) ATC2 (female) (13).
Resistance 5 15 z
HD465-7, HD605-7
20-607
(10)
TROUBLESHOOTING
TM-1
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY (IT ALWAYS INDICATES "FULL")
Action code Not set Failure code Controller code Not set Not set Trouble Fuel level gauge does not operate normally (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. Action of controller None in particular.
Problem that The fuel level gauge always indicates "FULL". appears on machine Related information If failure code "DJF1KA" is indicated, perform troubleshooting for it first.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T01. 3) Connect T-adapter. Fuel level: When FULL Between T01 (female) (1) (2) Fuel level: When EMPTY 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and T01. 3) Connect T-adapter. Wiring harness between ATC3B (female) (4) T01 (female) (1) Resistance between ATC3B (female) (4), T01 (female) (1) chassis ground Min. 1 Mz Resistance Max. 12 z Resistance 74 100 z
1 Fuel level sensor defective Possible causes and standard value in normal state 2 Ground fault in wiring harness
20-608
(10)
HD465-7, HD605-7
TROUBLESHOOTING
TM-2
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 Not set
Contents of trouble
Failure code Controller code Not set Not set
Abnormality in backup lamp and backup buzzer Trouble a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
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 Related information
Before starting troubleshooting, check that fuse (BT-1) (16) is normal. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R05 with normal one. 3) Turn the starting switch ON. When the backup lamp and buzzer relay (R05) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R05. Backup lamp and buzzer re- 3) Check the relay. 1 lay (R05) defective Between R05 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R05. 3) Check the relay. 4) Apply voltage between R05 (male) (1) (2). Apply 24 V between Resistance Max. 1 z Between R05 (male) (5) (6). (4) (3) Do not apply 24 V beResistance Min. 1 Mz tween (5) (6). No Yes Relay (R05) is normal. Relay (R05) is defective.
Possible causes and standard value 2 Diode (D05) defective in normal state
When diode (D05) is replaced, is failure repaired?
No Yes
1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and fuse (16) terminal. 3) Connect T-adapter. Wiring harness between fuse BT1 terminal Resistance Max. 1 z (16) R05 (female) (4) Disconnection in wiring har- Wiring harness between R05 (female) (5) Resistance Max. 1 z ness D05 (female) (1) 3 (Disconnection or defective Wiring harness between D05 (female) (2) contact) ATC5B (female) (2), and branch point of CNS Resistance Max. 1 z (female) (3) Wiring harness between R05 (female) (6) Resistance Max. 1 z chassis ground Wiring harness between R05 (female) (3) Resistance Max. 1 z CJT (female) (8) No 4 Joint connector (CJT) defec- When joint connector (CJT) is replaced, if failtive ure repaired? Yes Joint connector (CJT) is normal Joint connector (CJT) is defective
HD465-7, HD605-7
20-609
(10)
TROUBLESHOOTING
TM-2
b) Backup lamp is not turned ON (Backup buzzer is normal)

Action code Not set
Contents of trouble
Trouble
Abnormality in backup lamp and backup buzzer 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 normal).

Problem that When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is appears on machine normal). Related information Failure code is not displayed.
Cause 1 Backup lamp defective
Standard value in normal state/Remarks on troubleshooting Backup lamp bulb is not broken. Backup lamp bulb is broken. Backup lamp is normal Backup lamp is defective
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors B04 and CJT. ness 3) Connect T-adapter. 2 Possible causes (Disconnection or defective and standard value Wiring harness between CJT (female) (2) contact) in normal state B04 terminal
Resistance Max. 1 z No Joint connector (CJT) is normal Joint connector (CJT) is defective
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is failtive ure repaired? Yes
c) Backup buzzer is not turned ON (Backup lamp is normal)

Action code Not set
Contents of trouble
Trouble
Abnormality in backup lamp and backup buzzer 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 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). Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks ON troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors B05, B06, and CJT. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between CJT (female) (6) ness chassis ground 1 (Disconnection or defective Wiring harness between B06 terminal CJT contact) (female) (7) terminal Wiring harness between B05 terminal CJT (female) (1) terminal 2 Backup buzzer defective
Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
When results of Item a) and Cause 1 above are Backup buzzer is normal defective No Joint connector (CJT) is normal Joint connector (CJT) is defective
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is failtive ure repaired? Yes
20-610
(10)
HD465-7, HD605-7
TROUBLESHOOTING
TM-2
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON
Action code Not set
Contents of trouble
Abnormality in backup lamp and backup buzzer Trouble d) While shift lever is not operated, backup lamp and backup buzzer are turned ON
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 Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R05 with normal one. 3) Turn the starting switch ON. When the backup lamp and buzzer relay (R05) is replaced, is failure repaired? No Yes Relay (R05) is normal. Relay (R05) is defective.
1) Turn the starting switch OFF. 2) Disconnect connector R05. Backup lamp and buzzer re- 3) Check the relay. 1 lay (R05) defective Between R05 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R05. 3) Check the relay. 4) Apply voltage between R05 (male) (1) (2).
Apply 24 V between Resistance Max. 1 z Between R05 (male) (5) (6). (4) (3) Do not apply 24 V beResistance Min. 1 Mz tween (5) (6). 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and fuse (16) terminal. 3) Connect T-adapter. Voltage between R05 Wiring harness between R05 (fe- (female) (5), D05 (female) (1) chassis male) (5) D05 (female) (1) ground Wiring harness between D05 (feVoltage between D05 male) (2) ATC5B (female) (2), (female) (2) chassis and branch point of CNS (female) ground (3) Voltage between R05 Wiring harness between R05 (fe- (female) (3), CJT (female) (3) CJT (female) (8) male) (8) chassis ground Max. 1 V
Max. 1 V
Max. 1 V
Voltage between CJT Wiring harness between CJT (feMax. 1 V (female) (1), B05 termimale) (1) B05 terminal nal chassis ground Voltage between CJT Wiring harness between CJT (fe(female) (2), B04 termi- Max. 1 V male) (2) B04 terminal nal chassis ground
HD465-7, HD605-7
20-611
(10)
TROUBLESHOOTING
TM-2
20-612
(1)
HD465-7, HD605-7
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM (BK MODE)
Electrical system diagram related to retarder control .................................................................................. 20-704 Information in troubleshooting table ....................................................................................................... 20-706 Phenomenon code table ........................................................................................................................ 20-707 [2G42ZG] Accumulator (front): lowering of oil pressure (ZG).............................................................. 20-708 [2G43ZG] Accumulator (rear): lowering of oil pressure (ZG) .............................................................. 20-708 [D1C0KZ] Brake cutout relay: disconnection or short circuit (KZ) ....................................................... 20-709 [D5ZNKZ] Failure of front brake cutout output system (disconnection, grounding fault, short circuit) (if equipped): disconnection or short circuit (KZ) ................................................................ 20-711 [DB10KK] Retarder controller: lowering of source/input voltage (KK) ................................................. 20-713 [DB11KK] Main power line of retarder controller: lowering of source/input voltage (KK) .................... 20-715 [DB12KK] Retarder controller load power line: lowering of source/input voltage (KK) ........................ 20-717 [DB13KK] Direct power source line of retarder controller battery: lowering of source/input voltage (KK)................................................................................. 20-719 [DB19KM] Retarder controller wiring harness: mistake in operation or setting (KM) ........................... 20-720 [DB1SKQ] Wrong information on model selection: disagreement of model selection signals (KQ)..... 20-721 [DDD7KX] Failure in travel speed set switch system (if equipped): out of input signal range (KX) ..... 20-722 [DDD8KA] ARSC system switch system: disconnection (KA).............................................................. 20-724 [DDD8KB] ARSC system switch system: short circuit (KB) ................................................................. 20-725 [dGR2L8] Failure In retarder oil temperature sensor system: *see separate list (L8) ......................... 20-726 [DGR2L8] Brake oil temperature sensor (rear): *see separate list (L8)............................................... 20-727 [dHP4KX] Failure in suspension pressure sensor (FR) system (if equipped): out of input signal range (KX) .............................................................................................. 20-728 [DHP4KX] Failure in suspension pressure sensor (FR) system (if equipped): out of input signal range (KX) .............................................................................................. 20-730 [dHP5KX] Failure in suspension pressure sensor (FL) system (if equipped): out of input signal range (KX) .............................................................................................. 20-732 [DHP5KX] Failure in suspension pressure sensor (FL) system (if equipped): 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 (if equipped): out of input signal range (KX)........... 20-740 [DK11KX] Failure in acceleration sensor system (if equipped): out of input signal range (KX)........... 20-741 [DK51L5] Retarder lever potentiometer: *see separate list (L5) ......................................................... 20-742 [DK52KX] Dump lever potentiometer 1: out of input signal range (KX)............................................... 20-745 [DK53L8] Dump lever potentiometer 2: *see separate list (L8) .......................................................... 20-747 [DK54KX] Body positioner sensor: out of input signal range (KX) ...................................................... 20-748 [DKD0L6] Failure in steering speed sensor (if equipped): *see separate list (L6) .............................. 20-750 [dLt3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-752 [dLT3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-753 [DW35KZ] Failure in output system of auto suspension solenoid 1 (if equipped) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754 [DW36KZ] Failure in output system of auto suspension solenoid 2 (if equipped) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-755 [DW72KZ] Failure in kick-out solenoid output system (D_OUT3) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ) ................................................................ 20-756 [DW73KZ] Failure in hoist select valve output system (D_OUT5) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ) ................................................................ 20-758 [DK11K4] Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4) ......... 20-759-1 [DX11KA] Disconnection in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760 HD465-7, HD605-7
20-701
(10)
[DX11KB] [DX11KY] [DX11MA] [DX13KA] [DX13KB] [DX13KY] BK-1
BK-2 BK-3 BK-4
Short circuit in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761 Grounding fault in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): short circuit with power source line (KY) .................................... 20-762 Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)............. 20-762-1 Disconnection in output circuit of hoist EPC valve (A_OUT3): disconnection (KA)............ 20-763 Grounding fault in output circuit of hoist EPC valve (A_OUT3): short circuit (KB) ............. 20-764 Short circuit in output circuit of hoist EPC valve (A_OUT3): short circuit with power source line (KY) ......................................................................................................... 20-765 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 Retarder brake oil temperature gauge does not operate normally ..................................... 20-771 Inclination alarm is turned ON when dump body is raised (when machine is not inclined more than 15).................................................................................................................... 20-772 Touch up/down and cancellation cannot be performed ...................................................... 20-773
20-702
(10)
HD465-7, HD605-7
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
20-704
(2)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-705
(5)
TROUBLESHOOTING

Cause
20-706
(10)
HD465-7, HD605-7
TROUBLESHOOTING

Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
HD465-7, HD605-7
20-707
(10)
TROUBLESHOOTING
[2G42ZG], [2G43ZG]
[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG)

Action code E03
Contents of trouble
Failure code Controller code 2G42ZG BK
Trouble Accumulator (Front): Lowering of oil pressure (ZG)
The signal of the front accumulator oil pressure sensor lowers below 13.2 MPa {135 kg/cm2} while the 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)
Cause Possible causes Lowering of front accumula1 and standard value tor (brake) oil pressure in normal state 2 Retarder controller defective
Standard value in normal state/Remarks on troubleshooting The front accumulator (brake) oil pressure is normal. aIf the oil pressure is not normal, perform troubleshooting for hydraulic/mechanical system. If the front accumulator (brake) oil pressure is normal, the retarder controller is defective.
[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG)

Action code E03
Contents of trouble
Failure code Controller code 2G43ZG BK
Trouble Accumulator (Rear): Lowering of oil pressure (ZG)
The signal of the rear accumulator oil pressure sensor lowers below 8.83 MPa {90 kg/cm2} while the 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 Related information This failure can be checked in the monitoring function (Code: 35501)
Cause
The rear accumulator (brake) oil pressure is normal. Possible causes Lowering of rear accumula1 aIf the oil pressure is not normal, perform troubleshooting for hyand standard value tor (brake) oil pressure draulic/mechanical system. in normal state If the rear accumulator (brake) oil pressure is normal, the retarder 2 Retarder controller defective controller is defective.
20-708
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[D1C0KZ]
[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code E03
Contents of trouble
Failure code Controller code Brake cutout relay: Disconnection or short circuit (KZ) Trouble (Disconnection, grounding fault, or short circuit) D1C0KZ BK When the output to the brake cutout relay circuit is turned ON, an abnormally large current flows or any 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, ASR) Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R14 with normal one. 3) Turn the starting switch ON. When the brake cutout relay (R14) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. No Yes Relay (R14) is normal Relay (R14) is defective
Brake cutout relay (R14) deResistance 200 400 z Between R14 (male) (1) (2) fective 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. 4) Apply voltage between R14 (male) (1) (2). Between R14 (male) (3) (5) Apply 24 V between (1) (2) Resistance Max. 1 z
Possible causes and standard value in normal state 2
Do not apply 24 V beResistance Min. 1 M z tween (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between fuse BR- Voltage between BRC1 20 30 V (4) chassis ground 3-(12) BRC1 (female) (4) Disconnection in wiring har- Wiring harness between fuse BT- Voltage between R14 20 30 V 3-(12) R14 (female) (5) (5) chassis ground ness (Disconnection or defective 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1, BRC2, and R14. contact) 3) Connect T-adapter. Wiring harness between BRC2 (female) (1), Resistance Max. 1 z (12) R14 (female) (3) Wiring harness between R14 (female) (2) chassis ground Resistance Max. 1 z
Wiring harness between BRC1 (female) (13) Resistance Max. 1 z R14 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Connect T-adapter. Wiring harness between BRC1 (female) (13) R14 (female) (1) Resistance between BRC1 (female) (13), R14 (female) Min. 1 M z (1) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC1 (feBRC1 (female) (13) R14 male) (13), R14 (female) (1) (female) (1) chassis ground
Max. 1 V
HD465-7, HD605-7
20-709
(10)
TROUBLESHOOTING
[D1C0KZ]
20-710
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[D5ZNKZ]
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (IF EQUIPPED): DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E03
Contents of trouble
Failure code Controller code D5ZNKZ BK
Failure of front brake cutout output system (Disconnection, grounding Trouble fault, short circuit) (if equipped): Disconnection or short circuit (KZ) (Disconnection, grounding fault, or short circuit)
When the output to the front brake cutout switch circuit is turned ON, an abnormally large current flows 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. When the front brake cutout switch is turned ON, the front brake cutout system does not work. Or, the Problem that 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)
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector FBC. 3) Check the switch.
Front brake cutout switch defective
Between FBC (male) (1) (3)
Turn the front brake cutout switch OFF (Press it up). Turn the front brake cutout switch ON (Press it down).
Resistance Min. 1 M z Resistance Max. 1 z
aWhen the front brake cutout switch is turned ON (pressed down), the front brake is cut out (the front brake does not operate). 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter. 2 Disconnection in wiring har- Wiring harness between DPC2B (female) (4) Resistance Max. 1 z ness FBC (female) (3) (Disconnection or defective Wiring harness between fuse BTC-4 (8) FBC contact) Resistance Max. 1 z (female) (1) Wiring harness between FBC (female) (1) chassis ground Possible causes and standard value in normal state Ground fault in wiring har3 ness 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter. Wiring harness between DPC2B (female) (4) FBC (female) (3) Resistance between DPC2B (female) (4), FBC (female) (3) chassis ground Min. 1 M z Resistance Max. 1 z
Wiring harness between fuse Resistance between BTC-4 (8) FBC (female) (1) FBC (female) (1) In this case, the fuse is broken. chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between DPC2B (female) (4) FBC (female) (3)
Min. 1 M z
Voltage between DPC2B (female) (4), FBC (female) (3) Max. 1 V chassis ground
5 Machine monitor defective
1) Turn the starting switch OFF. 2) Disconnect connector DPC2B 3) Connect T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (4) chassis ground Turn the cutout switch OFF (Press it up). Turn the cutout switch ON (Press it down). Voltage Voltage 20 30 V Max. 1 V
HD465-7, HD605-7
20-711
(10)
TROUBLESHOOTING
[D5ZNKZ]
20-712
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DB10KK]
[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)

Action code E03
Contents of trouble
Failure code Controller code DB10KK BK
Trouble Retarder controller: Lowering of source/input voltage (KK)
The voltages of both main power source voltage circuit and direct power source voltage circuit are below 17 V.
Action of controller None in particular. (The controller works as long as possible.)

Problem that This failure does not have a serious effect on the machine. appears on machine
If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), (17) for grounding
fault. Cause 1 Battery defective Standard value in normal state/Remarks on troubleshooting 1) Test the battery voltage and specific gravity of the battery fluid. Battery voltage Specific gravity of battery fluid 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Wiring harness between BRC1 (female) (8), (16) chassis ground Resistance Max. 1 z Voltage Specific gravity Min. 24 V Min. 1.26
1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness Voltage between 2 (Disconnection or defective Wiring harness between battery, battery BRC1 (7) (8), relay terminal B, BRC1 (7) contact) (16) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between battery relay terminal M BRC1 (9), (17) 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 4) Connect the connector. Between BRC1 (7) (8), (16) 3 Retarder controller defective 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (9), (17) (8), (16) Voltage Voltage
20 30 V
Voltage between BRC1 (9), (17) 20 30 V (8), (16)
20 30 V
20 30 V
HD465-7, HD605-7
20-713
(10)
TROUBLESHOOTING
[DB10KK]
20-714
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DB11KK]
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code E03 Failure code Controller code DB11KK BK Trouble Main power line of retarder controller: Lowering of source/input voltage (KK)
Contents of trouble The difference between the main power source voltage and direct power source voltage is 5 V or more.

Problem that This failure does not have a serious effect on the machine. appears on machine Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (9) (17) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Wiring harness between BRC1 (female) (8), (16) chassis ground Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness Voltage between bat1 (Disconnection or defective Wiring harness between battery tery relay terminal B 20 30 V battery relay terminal B contact) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Voltage between Wiring harness between battery BRC1 (9), (17) (8), relay terminal M BRC1 (9), (17) (16) 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 2 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (9), (17) (8), (16) Voltage 20 30 V 20 30 V
HD465-7, HD605-7
20-715
(10)
TROUBLESHOOTING
[DB11KK]
20-716
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DB12KK]
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/ INPUT VOLTAGE (KK)
Action code E03 Failure code Controller code DB12KK BK Trouble Retarder controller load power line: Lowering of source/input 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. The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC, ASR) Failure codes (DHU2KX, DHU3KX) are displayed, too.
Related information If the fuse is broken, check the line between the fuse BRC1 (female) (4) (17) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R14 with normal one. 3) Turn the starting switch ON. When brake cutout relay (R14) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. No Yes Relay (R14) is normal. Relay (R14) is defective.
Brake cutout relay (R14) deResistance 200 400 z Between R14 (male) (1) (2) fective 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. 4) Apply voltage between R14 (male) (1) (2). Between R14 (male) (3) (5) Apply 24 V between (1) (2) Do not apply voltage between (1) (2) Resistance Max. 1 z Resistance Min. 1 M z
1) Turn the starting switch OFF. 2) Disconnect connectors R14. 3) Insert T-adapter. 4) Connect the connector. Disconnection in wiring har- Wiring harness between fuse BT-3 Voltage between R14 (female) (5) chassis ness (12) R14 (female) (5) 2 ground (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and R14. 3) Connect T-adapter. 20 30 V
Wiring harness between BRC2 (1), (12) R14 Resistance Max. 1 z (female) (5) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC2 (1), (12) chassis ground Voltage 20 30 V
HD465-7, HD605-7
20-717
(10)
TROUBLESHOOTING
[DB12KK]
20-718
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DB13KK]
[DB13KK] DIRECT POWER SOURCE LINE OF RETARDER CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code E03 Failure code Controller code DB13KK BK Trouble Direct power source line of retarder controller battery: Lowering of source/input voltage (KK)
Contents of trouble The direct power source voltage is below 5 V.

Problem that This failure does not have a serious effect on the machine. appears on machine Related information If the fuse is broken, check the line between the fuse BRC1 (female) (7) for grounding fault.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter.
Wiring harness between BRC1 (female) (8), Resistance Max. 1 z Disconnection in wiring har- (16) chassis ground ness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connector BRC1. contact) Possible causes 3) Insert T-adapter. and standard value 4) Connect the connector. in normal state Wiring harness between battery, Voltage between battery relay terminal B, BRC1 (7) 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 2 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (7) (8), (16) Voltage 20 30 V BRC1 (9), (17) (8), (16) 20 30 V
HD465-7, HD605-7
20-719
(10)
TROUBLESHOOTING
[DB19KM]
[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM)

Action code E03
Contents of trouble
Failure code Controller code DB19KM BK
Retarder controller wiring harness: Mistake in operation or setting Trouble (KM) (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 not agree with setting in the controller. The controller turns the all output circuits OFF. This failure is not recorded in the fault history. The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC, ASR) Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.
Standard value in normal state/Remarks on troubleshooting The connector of the connector check signal is connected normally. aConnector check signal connector: BRC3A (1) (OPEN), BRC5A (1) (CLOSE)
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector BRC5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between BRC5A (female) (1) contact) Resistance Max. 1 z chassis ground Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Connect T-adapter. Wiring harness between BRC3A (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4 Retarder controller Wiring harness between BRC5A (female) (1) Resistance Max. 1 z chassis ground Between BRC3A (female) (1) chassis ground Resistance Min. 1 M z Resistance between BRC3A (female) (1) Min. 1 M z chassis ground
20-720
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DB1SKQ]
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)
Action code E03 Failure code Controller code DB1SKQ BK Trouble Wrong information on model selection: Disagreement of model selection signals (KQ)
Since communication with the transmission controller (S-NET) is defective, model selection informaContents of trouble tion cannot be received or received model selection information is out of setting. Action of controller None in particular.
Problem that This failure does not have a serious effect on the machine. appears on machine Related information Other failures are detected, too. (Failure codes [DAFSKQ], [DAQAKR], [DAQSKQ] are displayed.)
Cause
Possible causes Transmission controller de- aIf the failure is not repaired by replacing the retarder controller, the 1 and standard value transmission controller is defective. fective in normal state aIf the failure is repaired by replacing the transmission controller, the 2 Retarder controller defective retarder controller is defective.
HD465-7, HD605-7
20-721
(10)
TROUBLESHOOTING
[DDD7KX]
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DDD7KX BK Failure in travel speed set switch system (if equipped): Out of inTrouble put signal range (KX) (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.
Cause
1) Turn the starting switch OFF. 2) Replace the travel speed set switch (ARSC SET switch). Travel speed set switch (AR1 Replace the travel Failure is not repaired. Switch is normal SC SET switch) defective speed set switch (ARFailure is repaired. Switch is defective SC SET switch). 1) Turn the starting switch OFF. 2) Disconnect connector RE3. 2 Register (250 z) defective 3) Connect T-adapter. Between RE3 (female) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector RE4. 3 Resistor (1,020 z) defective 3) Connect T-adapter. Between RE4 (female) (1) (2) Resistance 250 25 z
Resistance 1,020 102 z
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, ARC, RE3, and RE4. 3) Connect T-adapter. Wiring harness between BRC3A (female) (6) Resistance Disconnection in wiring har- RE3 (male) (1) ness 4 Possible causes Wiring harness between BRC3B (female) (15) Resistance (Disconnection or defective and standard value RE3 (male) (2) ARC (female) (1) contact) in normal state Wiring harness between RE4 (male) (1) ARC Resistance (female) (3) Wiring harness between RE4 (male) (2) ARC Resistance (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (6) (16) Voltage 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 5 Retarder controller defective 3) Insert T-adapter. When set switch is ON Resistance 1,020 102 z When set switch is Resistance 68 6.8 z TOUCH UP When set switch is Resistance 198 19.8 z TOUCH DOWN When set switch is CANCEL Resistance 418 41.8 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Approx. 5 V
Between BRC3B (female) (15) BRC3A (female) (16)
20-722
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDD7KX]
HD465-7, HD605-7
20-723
(1)
TROUBLESHOOTING
[DDD8KA]
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Action code E03 Failure code Controller code ARSC system switch system: Disconnection (KA) Trouble (When ARSC is set and ARSC system switch is ON) DDD8KA BK
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 This failure does not have a serious effect on the machine. appears on machine Related information
Cause
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between DPC2B (female) (1) contact) Resistance Max. 1 z ARSC (female) (3) 1) Turn the starting switch OFF. 2) Replace the ARSC system switch with normal one. ARSC system switch defec- 3) Turn the starting switch ON. 2 Possible causes tive When the ARSC system No System switch is normal and standard value switch is replaced with norYes System switch is defective in normal state mal one, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (1) chassis ground Turn the ARSC system switch ON (Press it up). Turn the ARSC system switch OFF (Press it down). Voltage Voltage 20 30 V Max. 1 V
20-724
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDD8KB]
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Action code E03 Failure code Controller code ARSC system switch system: Short circuit (KB) Trouble (When ARSC is set and ARSC system switch is ON) DDD8KB BK
Contents of trouble The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ARSC and DPC2B. 3) Connect T-adapter.
Wiring harness beVoltage between tween DPC2B (feDPC2B (female) (1), Voltage Max. 1 V male) (1) ARSC ARSC (female) (3) (female) (3) chassis ground 1) Turn the starting switch OFF. 2) Replace the ARSC system switch with normal one. Possible causes ARSC system switch defec- 3) Turn the starting switch ON. 2 and standard value tive When the ARSC system No System switch is normal in normal state switch is replaced with norYes System switch is defective mal one, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Turn the ARSC system Between switch ON (Press it up). DPC2B (1) chassis ground Turn the ARSC system switch OFF (Press it down).
Voltage Voltage
20 30 V Max. 1 V
HD465-7, HD605-7
20-725
(10)
TROUBLESHOOTING
[dGR2L8]
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: *SEE SEPARATE LIST (L8)
Action code E03 Failure code Controller code dGR2L8 BK Failure in retarder oil temperature sensor system: *See separate Trouble list (L8) (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.
This failure can be checked in the monitoring function (Code: 30200). When ARSC is not set or the ARSC system switch is OFF, failure code "DGR2L8" is displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter. Between T02 (male) (1) (2) Brake oil temperature: Resistance 37 50 k z 25C Brake oil temperature: Resistance 3.5 4.0 k z 100C
Retarder brake oil temperature sensor defective
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter. Wiring harness between BRC3B (female) (3) T02 (female) (1) Resistance between BRC3B (female) (3), T02 (female) Min. 1 M z (1) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective Brake oil temperature: Resistance 37 50 k z Between BRC3B (fe25C male) (3) BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 4.0 k z 100C
20-726
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGR2L8]
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE SEPARATE LIST (L8)
Action code E01 Failure code Controller code Brake oil temperature sensor (Rear): *See separate list (L8) Trouble (When ARSC is set and the ARSC system switch is OFF) DGR2L8 BK
Contents of trouble The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
This failure can be checked in the monitoring function (Code: 30200). When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed. Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter. Retarder brake oil temperaBrake oil temperature: 1 Resistance 37 50 k z ture sensor defective 25C Between T02 (male) (1) (2) Brake oil temperature: Resistance 3.5 4.0 k z 100C Cause
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter.
Wiring harness between Resistance between BRC3B BRC3B (female) (3) T02 (female) (3), T02 (female) Min. 1 M z (female) (1) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. Brake oil temperature: 3 Retarder controller defective Resistance 37 50 k z Between BRC3B (fe25C male) (3) BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 4.0 k z 100C
HD465-7, HD605-7
20-727
(10)
TROUBLESHOOTING
[dHP4KX]
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code dHP4KX BK Failure in suspension pressure sensor (FR) system (if equipped): Trouble Out of input signal range (KX) (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.
This failure can be checked in the monitoring function (Code: 32802, 32803) When ARSC is not set or the ARSC system switch is OFF, failure code "DHP4KX" is displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFR and PM6. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between BRC3A (female) (20) Resistance Max. 1 z ness SUFR (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z SUFR (female) (A) Wiring harness between PM6 (female) (2) Resistance Max. 1 z SUFR (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A SUFR and PM6. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between BRC3A (female) (20) SUFR (female) (C) Resistance between BRC3A (female) (20), SUFR (female) Min. 1 M z (C) chassis ground
Wiring harness between Resistance between PM6 PM6 (female) (2) SUFR (fe- (female) (2), SUFR (female) Min. 1 M z male) (B) (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) male) (9), SUFR (female) Max. 1 V SUFR (female) (C) (C) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector SUFR. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFR (B) (A) Between SUFR (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (20) (16)
Voltage Voltage
20 30 V 1.0 4.6 V
Voltage
1.0 4.6 V
20-728
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[dHP4KX]
HD465-7, HD605-7
20-729
(5)
TROUBLESHOOTING
[DHP4KX]
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DHP4KX BK Failure in suspension pressure sensor (FR) system (if equipped): Trouble Out of input signal range (KX) (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.

This failure can be checked in the monitoring function (Code: 32802, 32803) When ARSC is set and the ARSC system switch is ON, failure code "dHP4KX" is displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFR and PM6. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between BRC3A (female) (20) Resistance Max. 1 z ness SUFR (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z SUFR (female) (A) Wiring harness between PM6 (female) (14) Resistance Max. 1 z SUFR (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, SUFR and PM6. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between BRC3A (female) (20) SUFR (female) (C) Wiring harness between PM6 (female) (2) SUFR (female) (B) Resistance between BRC3A (female) (20), SUFR (female) Min. 1 M z (C) chassis ground Resistance between PM6 (female) (2), SUFR (female) Min. 1 M z (B) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) male) (9), SUFR (female) Max. 1 V SUFR (female) (C) (C) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector SUFR. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFR (B) (A) Between SUFR (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (20) (16)
Voltage Voltage
18 3 V 1.0 4.6 V
Voltage
1.0 4.6 V
20-730
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHP4KX]
HD465-7, HD605-7
20-731
(5)
TROUBLESHOOTING
[dHP5KX]
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code dHP5KX BK Failure in suspension pressure sensor (FL) system (if equipped): Trouble Out of input signal range (KX) (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.
This failure can be checked in the monitoring function (Code: 32802, 32803) When ARSC is not set or the ARSC system switch is OFF, failure code "DHP5KX" is displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFL and PM6. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between BRC3A (female) (19) Resistance Max. 1 z ness SUFL (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z SUFL (female) (A) Wiring harness between PM6 (female) (2) Resistance Max. 1 z SUFL (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A SUFL and PM6. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between BRC3A (female) (19) SUFL (female) (C) Wiring harness between PM6 (female) (2) SUFL (female) (B) Resistance between BRC3A (female) (19), SUFL (female) Min. 1 M z (C) chassis ground Resistance between PM6 (female) (2), SUFL (female) Min. 1 M z (B) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) male) (9), SUFL (female) (C) Max. 1 V SUFL (female) (C) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector SUFL. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFL (B) (A) Between SUFL (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (19) (16)
Voltage Voltage
18 3 V 1.0 4.6 V
Voltage
1.0 4.6 V
20-732
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[dHP5KX]
HD465-7, HD605-7
20-733
(5)
TROUBLESHOOTING
[DHP5KX]
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DHP5KX BK Failure in suspension pressure sensor (FL) system (if equipped): Trouble Out of input signal range (KX) (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.

This failure can be checked in the monitoring function (Code: 32802, 32803) When ARSC is set and the ARSC system switch is ON, failure code "dHP5KX" is displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFL and PM6. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between BRC3A (female) (19) Resistance Max. 1 z ness SUFL (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z SUFL (female) (A) Wiring harness between PM6 (female) (2) Resistance Max. 1 z SUFL (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, SUFL and PM6. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between BRC3A (female) (19) SUFL (female) (C) Wiring harness between PM6 (female) (2) SUFL (female) (B) Resistance between BRC3A (female) (19), SUFL (female) Min. 1 M z (C) chassis ground Resistance between PM6 (female) (2), SUFL (female) Min. 1 M z (B) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) male) (9), SUFL (female) (B) Max. 1 V SUFL (female) (C) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector SUFL. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FL) defective 5) Turn the starting switch ON. Between SUFL (B) (A) Between SUFL (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (19) (16)
Voltage Voltage
18 3 V 1.0 4.6 V
Voltage
1.0 4.6 V
20-734
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHP5KX]
HD465-7, HD605-7
20-735
(5)
TROUBLESHOOTING
[DHU2KX]
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT SIGNAL RANGE (KX)
Accumulator oil pressure sensor (Front): Out of input signal Trouble range (KX) DHU2KX BK Contents of trouble The signal circuit voltage of the front accumulator oil pressure sensor is below 0.5 V or above 4.5 V. E01 Action of controller None in particular.
Problem that This failure does not have a serious effect on the machine. appears on machine Related information This failure can be checked in the monitoring function (Code: 35500)
Action code
Failure code Controller code
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 and fuse BT3 terminal (12). 3) Insert T-adapter. 4) Connect the connector and fuse BT3 terminal (12). 5) Turn the starting switch ON. Voltage between Wiring harness between fuse BT3 BRC1 (5) chassis 20 30 V terminal(12) BRC1 (female) (5) ground Disconnection in wiring harness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCF. contact) 3) Connect T-adapter. Wiring harness between BRC3A (female) (9) Resistance Max. 1 z ACCF (female) (C) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z ACCF (female) (A) Wiring harness between BRC1 (female) (14) Resistance Max. 1 z ACCF (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ACCF. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (9) ACCF (female) (9), ACCF (female) Min. 1 M z (female) (C) (C) chassis ground Resistance between BRC1 Wiring harness between BRC1 (female) (14) ACCF (female) (3), ACCF (female) Min. 1 M z (female) (B) (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ACCF. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (9) ACCF male) (9), ACCF (female) Max. 1 V (female) (C) (C) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ACCF. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ACCF (B) (A) Between ACCF (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (14) BRC3A (16) BRC3A (9) (16) Voltage Voltage 20 30 V 0.5 4.5 V Voltage Voltage 20 30 V 0.5 4.5 V
Cause
Front accumulator oil pressure sensor defective
20-736
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU2KX]
HD465-7, HD605-7
20-737
(1)
TROUBLESHOOTING
[DHU3KX]
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL RANGE (KX)
Accumulator oil pressure sensor (Rear): Out of input signal Trouble range (KX) DHU3KX BK Contents of trouble The signal circuit voltage of the rear accumulator oil pressure sensor is below 0.5 V or above 4.5 V. E01 Action of controller None in particular.
Problem that This failure does not have a serious effect on the machine. appears on machine Related information This failure can be checked in the monitoring function (Code: 35501)
Action code
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BTC1 and fuse BT3 terminal (12). 3) Insert T-adapter. 4) Connect the connector and fuse BT3 terminal (12). 5) Turn the starting switch ON. Voltage between Wiring harness between fuse BT3 BRC1 (5) chassis 20 30 V Disconnection in wiring har- terminal (12) BRC1 (female) (5) ground ness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCR. contact) 3) Connect T-adapter. Wiring harness between BRC3A (female) (10) Resistance Max. 1 z ACCR (female) (C) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z ACCR (female) (A) Wiring harness between BRC1 (female) (14) Resistance Max. 1 z ACCR (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ACCR. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (10) (female) (10), ACCR (feMin. 1 M z ACCR (female) (C) male) (C) chassis ground Wiring harness between Resistance between BRC1 BRC1 (female) (14) ACCR (female) (3), ACCR (female) Min. 1 M z (female) (B) (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ACCR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (10) male) (10), ACCR (female) Max. 1 V ACCR (female) (C) (C) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ACCR. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ACCR (B) (A) Between ACCR (C) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (14) BRC3A (16) BRC3A (10) (16) Voltage Voltage 20 30 V 0.5 4.5 V Voltage Voltage 20 30 V 0.5 4.5 V
Cause
Rear accumulator oil pressure sensor defective
20-738
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU3KX]
HD465-7, HD605-7
20-739
(1)
TROUBLESHOOTING
[dK11KX]
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code dK11KX BK Failure in acceleration sensor system (if equipped): Out of input Trouble signal range (KX) (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.
If the failure code "DK11KX" related to the transmission controller is displayed, perform troubleshooting for it first. When ARSC is not set or the ARSC system switch is OFF, failure code "DK11KX" is displayed. Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between BRC3B (female) (11) contact) Resistance Max. 1 z ATC3B (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ATC3B. 3) Connect T-adapter. Possible causes Ground fault in wiring har2 Resistance between and standard value ness Wiring harness between BRC3B BRC3B (female) (11), in normal state (female) (11) ATC3B (female) Min. 1 M z ATC3B (female) (11) (11) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3B (female) (11) chassis ground Voltage 0.6 4.75 V
20-740
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK11KX]
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DK11KX BK Failure in acceleration sensor system (if equipped): Out of input Trouble signal range (KX) (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.

If the failure code "dK11KX" related to the transmission controller is displayed, perform troubleshooting for it first. When ARSC is set and the ARSC system switch is ON, failure code "dK11KX" is displayed. Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between BRC3B (female) (11) contact) Resistance Max. 1 z ATC3B (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ATC3B. 3) Connect T-adapter. Possible causes Ground fault in wiring har2 Resistance between and standard value ness Wiring harness between BRC3B BRC3B (female) (11), in normal state (female) (11) ATC3B (female) Min. 1 M z ATC3B (female) (11) (11) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3B (female) (11) chassis ground Voltage 0.6 4.75 V
HD465-7, HD605-7
20-741
(10)
TROUBLESHOOTING
[DK51L5]
[DK51L5] RETARDER LEVER POTENTIOMETER: *SEE SEPARATE LIST (L5)

Action code E03
Contents of trouble
Failure code Controller code Trouble Retarder lever potentiometer: *See separate list (L5) DK51L5 BK The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or, 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. Action of controller Limits the output for the solenoid to 70%. Turns the output for the solenoid OFF. The following appear, depending on the action of the controller. This failure does not have a serious effect on the machine. Problem that appears on machine The retarder cannot control finely. The retarder does not operate (The foot brake operates, however). Related information This failure can be checked in the monitoring function (Code: 33900, 34000, 34100). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, BRC3B, BRC5A, RE1, and RTL. 3) Connect T-adapter. Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between BRC2 (female) (16) RE1 (female) (1) Wiring harness between RE1 (female) (2) RTL (female) (1) Disconnection in wiring har- Wiring harness between BRC3A (female) (16) ness RTL (female) (3) 1 (Disconnection or defective Wiring harness between BRC3B (female) (16) contact) RTL (female) (2)
Wiring harness between BRC5A (female) (6) Resistance Max. 1 z RTL (female) (4) Wiring harness between BRC5A (female) (7) Resistance Max. 1 z RTL (female) (5) Wiring harness between RTL (female) (6) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B, and RE1, and RTL. 3) Connect T-adapter. Wiring harness between Resistance between BRC2 BRC2 (female) (16) RE1 (female) (16), RE1 (female) Min. 1 M z (female) (1) (1) chassis ground Wiring harness between Resistance between RE1 RE1 (female) (2) RTL (fe- (female) (2), RTL (female) Min. 1 M z male) (1) (1) chassis ground Wiring harness between Resistance between BRC3B BRC3B (female) (16) RTL (female) (16), RTL (female) Min. 1 M z (female) (2) (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and RTL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC2 (female) (16) RE1 (female) (1) Wiring harness between RE1 (female) (2) RTL (female) (1) Wiring harness between BRC3B (female) (16) RTL (female) (2) Voltage between BRC2 (female) (16), RE1 (female) (1) Max. 1 V chassis ground Voltage between RE1 (female) (2), RTL (female) (1) Max. 1 V chassis ground Voltage between BRC3B (female) (16), RTL (female) (2) Max. 1 V chassis ground
Possible causes and standard value in normal state 2 Ground fault in wiring harness
20-742
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK51L5]
Cause 4 Resistor (RE1) defective
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector RE1. 3) Connect T-adapter. Between RE1 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector RTL 3) Connect T-adapter. 4) Insert the connector. 5) Turn the starting switch ON. 6) Check the potentiometer. Between RTL (1) (3) Between RTL (2) (3) Voltage Voltage 4.1 4.8 V 0.3 4.7 V
Resistance
250 z
5 Retarder lever defective
1) Turn the starting switch OFF. 2) Disconnect connector RTL 3) Connect T-adapter. 4) Check the switch. Between RTL (male) (4) (6) Between RTL (male) (5) (6) Lever at OFF position Resistance Max. 1 z Lever at ON position Resistance Min. 1 M z
Lever at OFF position Resistance Min. 1 M z Lever at ON position Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and BRC3B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC2 (16) BRC3A (16) Voltage Between BRC3B (16) BRC3A (16) 1) Turn the starting switch OFF. 6 Retarder controller defective 2) Disconnect connector RTL. 3) Connect T-adapter. 4) Check the switch. Between BRC5A (female) (6) chassis ground Between BRC5A (female) (7) chassis ground Voltage
4.1 4.8 V 0.3 4.7 V
Lever at OFF position Resistance Max. 1 z Lever at ON position Resistance Min. 1 M z
Lever at OFF position Resistance Min. 1 M z Lever at ON position Resistance Max. 1 z
HD465-7, HD605-7
20-743
(10)
TROUBLESHOOTING
[DK51L5]
20-744
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DK52KX]
[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX)

Action code E03 Failure code Controller code Dump lever potentiometer 1: Out of input signal range (KX) Trouble (Out of input signal range of lever potentiometer 1 or 2) DK52KX BK
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 Related information This failure can be checked in the monitoring function (Code: 34400).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter.
Wiring harness between BRC3A (female) (6) Resistance Disconnection in wiring har- HSL (female) (4) ness 1 Wiring harness between BRC3B (female) (14) Resistance (Disconnection or defective HSL (female) (2) contact) Wiring harness between BRC3B (female) (12) Resistance HSL (female) (3) Wiring harness between BRC3A (female) (16) Resistance HSL (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (6) HSL (female) (6), HSL (female) (4) chassis ground Ground fault in wiring har- (female) (4) 2 ness Wiring harness between Resistance between BRC3B BRC3B (female) (14) HSL (female) (14), HSL (female) (female) (2) (2) chassis ground Possible causes and standard value in normal state
Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Min. 1 M z
Min. 1 M z
Wiring harness between Resistance between BRC3B BRC3B (female) (12) HSL (female) (12), HSL (female) Min. 1 M z (female) (3) (3) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (6) HSL male) (6), HSL (female) (4) Max. 1 V (female) (4) chassis ground Wiring harness between Voltage between BRC3B (feBRC3B (female) (14) HSL male) (14), HSL (female) (2) Max. 1 V (female) (2) chassis ground Voltage between BRC3B (feWiring harness between BRC3B (female) (12) HSL male) (12), HSL (female) (3) Max. 1 V (female) (3) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector HSL. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between HSL (4) (1) Between HSL (2) (1) Between HSL (3) (1) Voltage Voltage Voltage 4.6 5.4 V 0.3 4.7 V 0.3 4.7 V
4 Dump lever defective
HD465-7, HD605-7
20-745
(10)
TROUBLESHOOTING
[DK52KX]
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Insert T-adapter. Possible causes 4) Connect the connector. and standard value 5 Retarder controller defective 5) Turn the starting switch ON. in normal state Between BRC3A (6) (16) Voltage Between BRC3B (14) BRC3A (16) Between BRC3B (12) BRC3A (16) Voltage Voltage
4.1 4.8 V 0.3 4.7 V 0.3 4.7 V
20-746
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK53L8]
[DK53L8] DUMP LEVER POTENTIOMETER 2: *SEE SEPARATE LIST (L8)

Action code E03 Failure code Controller code DK53L8 BK Dump lever potentiometer 2: *See separate list (L8) Trouble (Out of total range of input signal voltage of lever potentiometer 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 The dump body does not operate. appears on machine Related information
This failure can be checked in the monitoring function (Code: 34300, 34301). If the failure code "DK52KX" is displayed, perform troubleshooting for it. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HSL. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between HSL (4) (1) Between HSL (2) (1) Between HSL (3) (1) Voltage Voltage Voltage 4.6 5.4 V 0.3 4.7 V 0.3 4.7 V
Possible causes 1 Dump lever defective and standard value in normal state
If the failure is not repaired by performing the troubleshooting in 1 2 Retarder controller defective above, the retarder controller is defective.
HD465-7, HD605-7
20-747
(10)
TROUBLESHOOTING
[DK54KX]
[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code E03 Failure code Controller code Body positioner sensor: Out of input signal range (KX) Trouble (Out of input signal range of lever potentiometer 1 or 2) DK54KX BK 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.
Contents of trouble The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
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).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between BRC3A (female)(6) Resistance ness B07 (female) (C) 1 (Disconnection or defective Wiring harness between BRC3B (female) (13) contact) Resistance B07 (female) (B) Wiring harness between BRC3A (female) (16) Resistance B07 (female) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A Ground fault in wiring har2 BRC3A (female) (6) B07 (female) (6), B07 (female) ness (female) (C) (C) chassis ground Wiring harness between Resistance between BRC3B BRC3B (female) (13) B07 (female) (13), B07 (female) (female) (B) (B) chassis ground Possible causes and standard value in normal state 3 Hot short in wiring harness
Max. 1 z Max. 1 z Max. 1 z
Min. 1 M z
Min. 1 M z
4 Body positioner defective
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (6) B07 male) (6), B07 (female) (C) Max. 1 V (female) (C) chassis ground Wiring harness between Voltage between BRC3B (feBRC3B (female) (13) B07 male) (13), B07 (female) (B) Max. 1 V (female) (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector B07. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between B07 (C) (A) Voltage 4.6 5.4 V 0.3 4.7 V
Between B07 (B) (A) Voltage 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (6) (16) Voltage Between BRC3B (13) BRC3A (16) Voltage
4.1 4.8 V 0.3 4.7 V
20-748
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK54KX]
HD465-7, HD605-7
20-749
(1)
TROUBLESHOOTING
[DKD0L6]
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (IF EQUIPPED): *SEE SEPARATE LIST (L6)
Action code E01 Failure code Controller code DKD0L6 BK Trouble Failure in steering speed sensor (if equipped): *See separate list (L6)
Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sensor Contents of trouble and no signals are input. Action of controller None in particular.
Problem that This failure does not have a serious effect on the machine. appears on machine Related information This failure can be checked in the monitoring function (Code: 35401).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and SR2. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between BRC3A (female) (12) Resistance Max. 1 z ness SR2 (female) (2) 1 (Disconnection or defective Wiring harness between BRC3A (female) (14) contact) Resistance Max. 1 z SR2 (female) (3) Wiring harness between BRC2 (female) (14) Resistance Max. 1 z SR2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and SR2. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between Resistance between BRC3A BRC3A (female) (14) SR2 (female) (14), SR2 (female) Min. 1 M z (female) (3) (3) chassis ground Wiring harness between BRC2 (female) (14) SR2 (female) (1) Resistance between BRC3B (female) (14), SR2 (female) Min. 1 M z (1) chassis ground
Possible causes and standard value in normal state 3 Steering speed sensor defective
1) Turn the starting switch OFF. 2) Disconnect connector SR2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Turn the steering wheel slowly. Between SR2 (1) (3) 1) Turn the starting switch OFF. 2) Disconnect connector SR2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between SR2 (2) (3) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC2 (14) (21) 4 Retarder controller defective 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Turn the steering wheel slowly. Between BRC3A (12) (14) Voltage 10 13 V Voltage See FIG-1. Voltage 10 13 V
Voltage
See FIG-1.
20-750
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DKD0L6]
HD465-7, HD605-7
20-751
(1)
TROUBLESHOOTING
[dLt3KA]
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Action code E01
Contents of trouble
Failure code Controller code dLt3KA BK
Trouble
Transmission output shaft speed sensor: Disconnection (KA) (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 input.
This failure can be checked in the monitoring function (Code: 31400). When ARSC is not set or the ARSC system switch is OFF, failure code "dLT3KA" is displayed. Cause Wrong adjustment of trans1 mission output shaft speed sensor Standard value in normal state/Remarks on troubleshooting Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 1 turn. aFor details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor". 1) Turn the starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) (2) Resistance 500 1,000 z Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between BRC3A (female) (13) Resistance Max. 1 z (Disconnection or defective CN5 (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z CN5 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ATC3A. 4 Retarder controller defective 3) Connect T-adapter. Between BRC3A (female) (13) (14) Resistance 500 1,000 z
20-752
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[dLT3KA]
[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Action code E03
Contents of trouble
Failure code Controller code dLT3KA BK
Trouble
Transmission output shaft speed sensor: Disconnection (KA) (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 input.
This failure can be checked in the monitoring function (Code: 31400). When ARSC is set and the ARSC system switch is ON, failure code "dLT3KA" is displayed. Cause Wrong adjustment of trans1 mission output shaft speed sensor Standard value in normal state/Remarks on troubleshooting Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 1 turn. aFor details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor". 1) Turn the starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) (2) Resistance 500 1,000 z Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between BRC3A (female) (13) Resistance Max. 1 z (Disconnection or defective CN5 (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z CN5 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ATC3A. 4 Retarder controller defective 3) Connect T-adapter. Between BRC3A (female) (13) (14) Resistance 500 1,000 z
HD465-7, HD605-7
20-753
(10)
TROUBLESHOOTING
[DW35KZ]
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E01
Contents of trouble
Failure code Controller code DW35KZ BK
Failure in output system of auto suspension solenoid 1 (if Trouble equipped) (Disconnection, grounding fault, short circuit): Disconnection or short circuit (KZ)
When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows 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 auto suspension solenoid 1 OFF.
Problem that The auto suspension system does not operate. appears on machine Related information This failure can be checked in the monitoring function (Code: 39300).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector S04. Auto suspension solenoid 1 3) Insert T-adapter. 1 defective Between S04 (female) (1) (2) Between S04 (female) (1), (2) chassis ground Possible causes and standard value in normal state
Resistance 15 35 z Resistance Min. 1 M z
1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and S04. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC1 (female) (1) Resistance Max. 1 z (Disconnection or defective S04 (female) (1) contact) Wiring harness between S04 (female) (2) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3 Retarder controller defective 3) Insert T-adapter. Between BRC1 (female) (1) chassis ground Resistance 15 20 z
20-754
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DW36KZ]
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E01
Contents of trouble
Failure in output system of auto suspension solenoid 2 (if Trouble equipped) (Disconnection, grounding fault, short circuit): Disconnection or short circuit (KZ)
When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows 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 auto suspension solenoid 2 OFF.
Problem that The auto suspension system does not operate. appears on machine Related information This failure can be checked in the monitoring function (Code: 39301).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector S05. Auto suspension solenoid 2 3) Insert T-adapter. 1 defective Between S05 (female) (1) (2) Between S05 (female) (1), (2) chassis ground Possible causes and standard value in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and S05. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC1 (female) (2) (Disconnection or defective Resistance Max. 1 z S05 (female) (1) contact) Wiring harness between S05 (female) (2) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3 Retarder controller defective 3) Insert T-adapter. Between BRC1 (female) (2) chassis ground Resistance 15 20 z
HD465-7, HD605-7
20-755
(10)
TROUBLESHOOTING
[DW72KZ]
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E01
Contents of trouble
Failure in kick-out solenoid output system (D_OUT3) (DisconTrouble nection, grounding fault, short circuit): Disconnection or short circuit (KZ)
When the output to the dump lever kick-out solenoid circuit is ON, a too large current flows 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 dump lever kick-out solenoid OFF.
Problem that Detent lock is not applied to the dump lever. appears on machine Related information This failure can be checked in the monitoring function (Code: 34700).
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and LK0. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between LK0 (female) (2) (Disconnection or defective Resistance Max. 1 z chassis ground contact) Wiring harness between BRC1 (female) (11) Resistance Max. 1 z LK0 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and LK0. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC1 (female) (11) LK0 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector LK0. 3) Connect T-adapter. Between LK0 (male) (1) (2) Resistance 39 z 5% Between LK0 (male) (1), (2) chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connector LK0. 4 Retarder controller defective 3) Connect T-adapter. Between BRC1 (female) (11) chassis ground Resistance 39 z 5% Voltage between BRC1 (female) (11), LK0 (female) (1) chassis ground
Possible causes 2 Hot short in wiring harness and standard value in normal state
Max. 1 V
Dump lever kick-out solenoid defective
20-756
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DW72KZ]
HD465-7, HD605-7
20-757
(1)
TROUBLESHOOTING
[DW73KZ]
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code E03
Contents of trouble
Failure in hoist select valve output system (D_OUT5) (DisconTrouble nection, grounding fault, short circuit): Disconnection or short circuit (KZ)
When the output to the dump lever select valve solenoid circuit is ON, a too large current flows or any 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 The dump body does not operate. appears on machine Related information This failure can be checked in the monitoring function (Code: 34800).
Cause
1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and HSOL. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between HSOL (female) (B) 1 Resistance Max. 1 z (Disconnection or defective chassis ground contact) Wiring harness between BRC1 (female) (12) Resistance Max. 1 z HSOL (female) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and HSOL. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between Wiring harness between BRC1 BRC1 (female) (12), (female) (12) HSOL (female) (A) HSOL (female) (A) chassis ground
2 Hot short in wiring harness Possible causes and standard value in normal state
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector HSOL. Dump lever select valve so- 3) Connect T-adapter. 3 lenoid defective Between HSOL (male) (A) (B) Between HSOL (male) (A), (B) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector HSOL. 4 Retarder controller defective 3) Connect T-adapter.
Between BRC1 (female) (12) chassis ground Resistance 15 35 z
20-758
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DW73KZ]
HD465-7, HD605-7
20-759
(1)
TROUBLESHOOTING
[DK11K4]
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: UNCONTROLLABLE (K4)
Action code E03 Failure code Controller code DK11K4 BK Trouble Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4)
Contents of trouble The proportional solenoid pressure reducing valve does not return (does not move).
Action of controller Resets the retarder solenoid output.

Problem that The retarder (rear brake), ARSC, and overrun prevention system do not operate. appears on machine Related information
The state of the retarder oil pressure switch can be checked with the monitoring function (Code: 34100). Cause Standard value in normal state/Remarks on troubleshooting
Defective proportional Check proportional solenoid pressure reducing valve of rear wheel 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve of rear wheel 1) Turn starting switch OFF. 2) Disconnect connector RESW. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between RESW (female) (1) (2) Oil pressure ON Oil pressure OFF Resistance Max. 1 z Resistance Min. 1 M z
Defective retarder oil pressure switch
1) Turn starting switch OFF. 2) Disconnect connector BRC5A and RESW. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC5A (female) (4) RESW (female) (1) Resistance between BRC5A (female) (4), RESW (female) Max. 1 z (1) chassis ground
1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC5A (female) (4) RESW (female) (1) Voltage between BRC5A (female) (4), RESW (female) Max. 1 V (1) chassis ground
1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 5 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5A (4) Oil pressure ON shassis ground Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
20-759-1
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK11K4]
HD465-7, HD605-7
20-759-2
(5)
TROUBLESHOOTING
[DX11KA]
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): DISCONNECTION (KA)
Action code E03
Contents of trouble
Failure code Controller code DX11KA BK
Disconnection in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Disconnection (KA)
When the output to the rear wheel pressure reducing valve solenoid circuit is ON, any current does not 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).
Cause
1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) (2) Between RETV (female) (1), (2) chassis ground Possible causes and standard value in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC2 (female) (7) (Disconnection or defective Resistance Max. 1 z RETV (female) (1). contact) Wiring harness between BRC2 (female) (17) Resistance Max. 1 z RETV (female) (2). 1) Turn the starting switch OFF. 2) Disconnect connector BRC. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) (17) Resistance 10 30 z
20-760
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX11KB]
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT (KB)
Action code E03
Contents of trouble
Failure code Controller code DX11KB BK
Short circuit in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit (KB)
When the output to the rear wheel pressure reducing valve solenoid circuit is ON, a too large current flows.
Cause
1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) (2) Between RETV (female) (1), (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. 3) Connect T-adapter.
Resistance between Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (9), 2 cuit in wiring harness (female) (7) RETV (female) (1). RETV (female) (1) chassis ground.
Min. 1 M z
Wiring harness between BRC2 (female) (7) RETV (female) (1) and between BRC (female) (17) RETV (female) Min. 1 M z (2) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) (17) Resistance 10 30 z
HD465-7, HD605-7
20-761
(10)
TROUBLESHOOTING
[DX11KY]
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT WITH POWER SOURCE LINE (KY)
Action code E03
Contents of trouble
Failure code Controller code DX11KY BK
Grounding fault in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit with power source line (KY)
While the output to the rear wheel pressure reducing valve solenoid circuit is OFF, some current is flowing.
Cause
1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) (2) Between RETV (female) (1), (2) chassis ground Possible causes and standard value in normal state 2 Hot short in wiring harness 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. 3) Connect T-adapter.
Voltage between Wiring harness between BRC2 BRC2 (female) (7), (female) (7) RETV (female) (1). RETV (female) (1) chassis ground.
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) (17) Resistance 10 30 z
20-762
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX11MA]
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: MALFUNCTION (MA)
Action code E03 Failure code Controller code DX11MA BK Trouble Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)
Contents of trouble The proportional solenoid pressure reducing valve does not operate (does not move).
Action of controller Resets the retarder solenoid output.

Problem that The retarder (rear brake), ARSC, and overrun prevention system do not operate. appears on machine Related information
The state of the retarder oil pressure switch can be checked with the monitoring function (Code: 34100). Cause Standard value in normal state/Remarks on troubleshooting
Defective proportional sole- Check the proportional solenoid pressure reducing valve of rear 1 noid pressure reducing wheel and repair or replace it, if it has abnormality (mechanical failvalve of rear wheel ure). 1) Turn starting switch OFF. 2) Disconnect connector RESW. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between RESW (female) (1) (2) Possible causes and standard value in normal state Oil pressure ON Oil pressure OFF Resistance Max. 1 z Resistance Min. 1 M z
Defective retarder oil pressure switch
1) Turn starting switch OFF. 2) Disconnect connector BRC5A RESW. Disconnection in wiring har- 3) Connect T-adapter. 3 ness Wiring harness between Resistance between BRC5A BRC5A (female) (4) (female) (4), RESW (female) Max. 1 z RESW (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5A (4) Oil pressure ON chassis ground (16) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
HD465-7, HD605-7
20-762-1
(10)
TROUBLESHOOTING
[DX13KA]
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): DISCONNECTION (KA)
Action code E03 Failure code Controller code DX13KA BK Trouble Disconnection in output circuit of hoist EPC valve (A_OUT3): 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 The dump body does not operate. appears on machine Related information This failure can be checked in the monitoring function (Code: 34900, 34901).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HEPC. 3) Insert T-adapter. Between HEPC (female) (1) (2) Between HEPC (female) (1), (2) chassis ground Resistance 15 20 z Resistance Min. 1 M z
Dump EPC valve solenoid defective
1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC2 (female) (10) Resistance Max. 1 z (Disconnection or defective HEPC (female) (1). contact) Wiring harness between BRC2 (female) (20) Resistance Max. 1 z HEPC (female) (1). 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. 19. Between BRC2 (female) (10) (20) Resistance 15 20 z
HD465-7, HD605-7
20-763
(10)
TROUBLESHOOTING
[DX13KB]
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DX13KB BK Grounding fault in output circuit of hoist EPC valve (A_OUT3): Trouble Short circuit (KB)
Contents of trouble When the output to the dump EPC valve solenoid circuit is ON, a too large current flows.
The controller turns the output to the dump select valve solenoid OFF. Action of controller The controller turns the output to the dump EPC valve solenoid OFF.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HEPC. 3) Insert T-adapter. Between HEPC (female) (1) (2) Between HEPC (female) (1), (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. 3) Connect T-adapter. Resistance 15 20 z Resistance Min. 1 M z
Resistance between BRC2 (female) (10), Grounding fault or short cir- Wiring harness between BRC2 2 (female) (10) HEPC (female) (1). HEPC (female) (1) cuit in wiring harness chassis ground.
Min. 1 M z
Wiring harness between BRC2 (female) (10) HEPC (female) (1) and between BRC2 (female) (20) HEPC (fe- Min. 1 M z male) (2) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (10) (20) Resistance 15 20 z
20-764
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX13KY]
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT WITH POWER SOURCE LINE (KY)
Action code E03 Failure code Controller code DX13KY BK Trouble Short circuit in output circuit of hoist EPC valve (A_OUT3): Short circuit with power source line (KY)
Contents of trouble While the output to the dump EPC valve solenoid circuit is OFF, some large current is flowing.
The controller turns the output to the dump select valve solenoid OFF. The controller turns the output to the dump EPC valve solenoid OFF.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HEPC. 3) Insert T-adapter. Between HEPC (female) (1) (2) Between HEPC (female) (1), (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. 3) Connect T-adapter. 4) Turn the starting switch ON. Resistance 15 20 z Resistance Min. 1 M z
Voltage between Hot short in wiring harness Wiring harness between BRC2 BRC2 (female) (10), 2 (Contact with power source (female) (10) HEPC (female) (1). HEPC (female) (1) wiring harness) chassis ground. Voltage between Wiring harness between BRC2 BRC2 (female) (20), (female) (20) HEPC (female) (2). HEPC (female) (2) chassis ground. 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (10) (20)
Max. 1 V
Max. 1 V
Resistance 15 20 z
HD465-7, HD605-7
20-765
(10)
TROUBLESHOOTING
[DX13KY]
20-766
(1)
HD465-7, HD605-7
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 Not set Failure code Controller code Not set BK Parking brake does not operate normally Trouble a) When the parking brake switch is set in the OFF position, the 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 Related information
Before performing the troubleshooting, check that fuse (BT4) (4) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. When parking brake switch (R33) is disconnected, does parking brake operate? No Yes Parking brake switch (R33) is normal Parking brake switch (R33) is defective
1) Turn the starting switch OFF. 2) Disconnect connector R33. Parking brake switch defec- 3) Connect T-adapter. 1 tive Set the parking brake switch in PARK. Between R33 (male) (1) (2) Set the parking brake switch in OFF. Set the parking brake switch in PARK. Between R33 (male) (1) (3) Set the parking brake switch in OFF. 1) Turn the starting switch OFF. 2) Disconnect connector PSOL Parking brake solenoid de- 3) Connect T-adapter. 2 fective Between PSOL (male) (1) (2) Possible causes and standard value in normal state Between PSOL (male) (1), (2) chassis ground 1) Turn the starting switch OFF. 2) Replace R19 with normal one. 3) Turn the starting switch ON. When parking brake safety relay (R19) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. 3 Parking brake safety relay (R19) defective
Resistance Min. 1 M z Resistance Max. 1 z Resistance Max. 1 z Resistance Min. 1 M z
No Yes
Relay (R19) is normal Relay (R19) is defective
Resistance 200 400 z Between R19 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. 4) Apply voltage between R19 (male) (1) (2). Between R19 (male) (3) (5) Apply 24 V between (1) (2). Do not apply 24 V between (1) (2). Apply 24 V between (1) (2). Do not apply 24 V between (1) (2). Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z
Between R19 (male) (3) (6)
HD465-7, HD605-7
20-767
(10)
TROUBLESHOOTING
BK-1
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R19, R33, PSOL, fuse BT4 (4). 3) Connect T-adapter.
Wiring harness between fuse BT4 (4) R19 Possible causes Disconnection in wiring har- (female) (5), R33 (female) (3) and standard value ness 4 Wiring harness between R19 (female) (1), (3) in normal state (Disconnection or defective R33 (female) (1) contact) Wiring harness between R33 (female) (2) PSOL (female) (1) Wiring harness between PSOL (female) (2) chassis ground
Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
20-768
(10)
HD465-7, HD605-7
TROUBLESHOOTING
BK-1
b) When the parking brake switch is set in the PARK position, the parking brake does not work
Action code Not set Failure code Controller code Not set Not set Parking brake does not operate normally Trouble b) When the parking brake switch is set in the PARK position, the 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 Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R33. 3) Connect T-adapter.
Between R33 Parking brake switch defec- (male) (1) (2) 1 tive
Set the parking brake switch Resistance Min. 1 M z in PARK. Set the parking brake switch Resistance Max. 1 z in OFF. Set the parking brake switch Resistance Max. 1 z in PARK. Set the parking brake switch Resistance Min. 1 M z in OFF.
1) Turn the starting switch OFF. 2) Replace R19 with normal one. 3) Turn the starting switch ON. When parking brake safety relay (R19) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. Parking brake safety relay 2 (R19) defective Between R19 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. 4) Apply voltage between R19 (male) (1) (2). Between R19 (male) (3) (5) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z No Yes Relay (R19) is normal Relay (R19) is defective
Do not apply 24 V beResistance Min. 1 M z tween (1) (2). Apply 24 V between (1) (2). Resistance Min. 1 M z
Do not apply 24 V beResistance Max. 1 z tween (1) (2).
1) Turn the starting switch OFF. 2) Disconnect connectors R33 and PSOL. 3) Connect T-adapter. 3 Hot short in wiring harness Voltage between R33 Wiring harness between R33 (fe- (female) (2), PSOL (feMax. 1 z male) (2) PSOL (female) (1) male) (1) chassis ground
HD465-7, HD605-7
20-769
(10)
TROUBLESHOOTING
BK-1
20-770
(1)
HD465-7, HD605-7
TROUBLESHOOTING
BK-2
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY
Action code Not set Failure code Controller code Not set Not set Trouble Retarder brake oil temperature gauge does not operate normally (When ARSC is not set or ARSC system switch is OFF)
Contents of trouble The signal circuit voltage of the retarder brake oil temperature gauge is below 0.75 V.
Problem that This failure does not have a serious effect on the machine. appears on machine When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed. Related information This failure can be checked in the monitoring function (Code: 30200).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter.
Retarder brake oil temperature gauge defective
Between T02 (male) (1) (2)
Brake oil temperature: Resistance 37 50 kz 25C Brake oil temperature: Resistance 3.5 4.0 kz 100C
Possible causes and standard value 2 Hot short in wiring harness in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC3B (female) (3) T02 (female) (1) Voltage between BRC3B (female) (3), T02 (female) (1) chassis ground
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective Brake oil temperature: Resistance 37 50 kz Between BRC3B (fe25C male) (3) BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 4.0 kz 100C
HD465-7, HD605-7
20-771
(10)
TROUBLESHOOTING
BK-3
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15)
Action code Not set Failure code Controller code Not set Not set Trouble Inclination alarm is turned ON when dump body is raised (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) Action of controller None in particular.
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) Related information
If the inclination alarm is turned ON while the machine is incline more than 15, it is not defective (it is normal). This failure can be checked in the monitoring function (Code: 30200). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SR3. 3) Connect T-adapter. 1 Inclination sensor defective Between SR3 (male) (1) (2) Inclination is below 15 Resistance Max. 1 z Inclination is 15 or more Resistance Min. 1 M z
1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors BRC5A and SR3. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between BRC5A (female) (12) contact) Resistance Max. 1 z SR3 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective Between BRC5A (female) (12) chassis ground Inclination is below 15 Resistance Max. 1 z Inclination is 15 or more Resistance Min. 1 M z
20-772
(10)
HD465-7, HD605-7
TROUBLESHOOTING
BK-4
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED

Action code Not set Failure code Controller code Not set Not set Trouble Touch up/down and cancellation cannot be performed. (When ARSC is set and ARSC system switch is ON)
Contents of trouble Touch up/down and cancellation cannot be performed.
Problem that Touch up/down and cancellation cannot be performed. appears on machine Related information If failure code "DDD7KX" is displayed, perform troubleshooting for it.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (ARFailure is not repaired. Switch is normal Replace the travel SC SET switch) defective speed set switch (ARFailure is repaired. Switch is defective SC SET switch). 1) Turn the starting switch OFF. 2) Disconnect connector RE3. 3) Connect T-adapter. Between RE3 (female) (1) (2) Resistance 250 25 z
2 Register (250 z) defective
1) Turn the starting switch OFF. 2) Disconnect connector RE4. 3 Resistor (1,020 z) defective 3) Connect T-adapter. Between RE4 (female) (1) (2) Resistance 1,020 102 z 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3A, ARC, and RE4. ness Possible causes 3) Connect T-adapter. 4 (Disconnection or defective and standard value Wiring harness between BRC3A (female) (16) contact) in normal state Resistance Max. 1 z ARC (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between BRC3A (6) (16) 1) Turn the starting switch OFF. 5 Retarder controller defective 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. When set switch is ON Between BRC3B (female) (15) BRC3A (female) (16) When set switch is TOUCH UP When set switch is TOUCH DOWN Resistance 1,020 102 z Resistance 68 6.8 z Resistance 198 19.8 z Voltage Approx. 5 V
When set switch is CANCEL Resistance 418 41.8 z
HD465-7, HD605-7
20-773
(10)
TROUBLESHOOTING
BK-4
20-774
(1)
HD465-7, HD605-7
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE)
Electrical system diagram related to payload meter.................................................................................... 20-802 Service codes of payload meter (card type) and contents of self-diagnosis ....................................... 20-804 Information in troubleshooting table........................................................................................................ 20-807 Phenomenon code table ......................................................................................................................... 20-808 LC- 1 When starting switch is turned ON, any item is not displayed .................................................... 20-809 LC- 2 After starting switch is turned ON, all external pilot lamps do not light up .................................. 20-811 LC- 3 External lamps light up while condition for lighting is not set...................................................... 20-814 LC- 4 Lighting level of external pilot lamps is abnormal ....................................................................... 20-816 LC- 5 Cycle data and engine ON/OFF data not recorded (charge level signal system: judges that engine is stopped) ...................................................... 20-818 LC- 6 Calibration cannot be performed and displayed clock does not conform to condition (shift lever "N" position signal system)........................................................................................ 20-819 LC- 7 Displayed logic is abnormal........................................................................................................ 20-821 a) When loaded dump truck starts traveling, "0" is kept displayed............................................ 20-821 b) After loaded dump truck start traveling, display of odometer does not increase................... 20-821 c) When travel speed exceeds limit speed, "SP:SP" does not go off........................................ 20-821 d) Integrated pay load is not displayed ..................................................................................... 20-822 e) Displayed and saved pay load is not correct ........................................................................ 20-823 LC- 8 Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in "FLOAT" position while truck is not dumping)............................................................................. 20-824 LC- 9 Payload meter displays "F:09" (lowering of internal backup battery voltage) ............................. 20-826 LC-10 Payload meter displays " :FULL" (data saving memory is full) ................................................ 20-826 LC-11 Payload meter displays "F-20" : failure in power source of suspension pressure sensor and clinometer system....................................................................................................................... 20-827 LC-12 Payload meter displays "F-21" "F-24" : disconnection or grounding fault in suspension sensor signal system .................................................................................................................. 20-829 LC-13 Payload meter displays "F-25" "F-28" : short circuit with power source (Hot short) in suspension sensor signal system ........................................................................................... 20-832 LC-14 Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) ... 20-834 LC-15 Payload meter displays "F:43" "F:45" (short circuit with power source (Hot short) in external pilot lamp relay system) ............................................................................................ 20-835 LC-16 Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) ........... 20-837 LC-17 External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck travels for 160 m after it is loaded ............................................................................ 20-839 LC-18 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal system ........................................................................................................................................ 20-840 LC-19 Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal system ........................................................................................................................................ 20-842 LC-20 Payload meter displays "F:18" (disconnection in charge level signal system) ........................... 20-844
HD465-7, HD605-7
20-801
(10)
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802
(2)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-803
(2)
TROUBLESHOOTING
SERVICE CODES OF PAYLOAD METER (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS
SERVICE CODES OF PAYLOAD METER DIAGNOSIS
(CARD TYPE) AND CONTENTS OF SELF(Card type). (They are not displayed on the
The following are displayed on the display unit of Payload Meter monitor panel.)
Priority of display
1
Contents
Dump lever is not in FLOAT position (Truck is not dumping) Memory card is not inserted Backup battery voltage is lowered Cycle data memory is FULL Engine ON/OFF data is FULL
Service code
b-FL lighting up b-FL lighting up Cd flashing F-09 flashing
External pilot lamps

All lighting up
2 3
4 Abnormality warning data memory is FULL Data memory of integrated pay load and total number of cycle is FULL 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Disconnection of terminal R Abnormality in sensor power source (18 V) Short circuit with chassis ground or disconnection in front left suspension pressure sensor system Short circuit with chassis ground or disconnection in front right suspension pressure sensor system Short circuit with chassis ground or disconnection in rear left suspension pressure sensor system Short circuit with chassis ground or disconnection in rear right suspension pressure sensor system Short circuit with power source in front left suspension pressure sensor system Short circuit with power source in front right suspension pressure sensor system Short circuit with power source in rear left suspension pressure sensor system Short circuit with power source in rear right suspension pressure sensor system Short circuit with chassis ground or disconnection in clinometer system Short circuit with power source of clinometer system Calibration has not been performed or RAM is abnormal Short circuit in external pilot lamp G relay Short circuit in external pilot lamp Y relay Short circuit in external pilot lamp R relay Pay load in cycle data is inaccurate [See (*2) in page 20-806] Higher than limit speed
See (*1) on next page.
F-18 flashin F-20 flashin F-21 flashin F-22 flashin F-23 flashin F-24 flashin F-25 flashin F-26 flashin F-27 flashin F-28 flashin F-31 flashin F-32 flashin F CAL flashin F-43 flashin F-44 flashin F-45 flashin L. bad flashin SP : SP flashin F-71 flashin F-73 flashin F-80 flashin F-81 flashin F-91 flashin F-92 flashin F-93 flashin F-94 flashin F-95 flashin F-96 flashin F-97 flashin F-98 flashin
All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing All flashing Related lamps While stopped: Kept lighted up While traveling: Turned OFF Other lamps While loading: Normal operation While stopped without loading: Flashing While traveling: Turned OFF
23
Communication defective or wrong option code setting
20-804
(1)
HD465-7, HD605-7
TROUBLESHOOTING
(*1) Alarm displayed when memory is FULL 1. Cycle data 1) If the number of saved cycles reaches 2600 (the remaining capacity is 300 cycles or less), the following is repeated. L : FUL flashes 7 times. : flashes 1 time. 2) If the number of saved cycles reaches 2900 (the remaining capacity is 0 cycle), the following is repeated. L : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the number of saved cycles exceeds 2900, the new cycles are saved as 2901st cycle, 2902nd cycle ---. Each time the new cycle is saved, however, the cycle data are deleted from the oldest one. (The alarm of "2)" above is maintained.) 2. Engine ON/OFF data 1) If the number of saved ON/OFF times reaches 105 (the remaining capacity is 10 times or less), the following is repeated 2 times and then goes off. E : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the number of saved ON/OFF times reaches 115 (the remaining capacity is 0 time), the following is repeated 2 times and then goes off. E : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the number of saved ON/OFF times exceeds 115, the new ON/OFF times are saved as 116th time, 117th time ---. Each time the new ON/OFF time is saved, however, the engine ON/OFF data are deleted from the oldest one. 3. Abnormality/Warning data 1) If the number of saved abnormalities/ warnings reaches 220 (the remaining capacity is 10 abnormalities/warnings or less), the following is repeated. E : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the number of saved abnormalities/ warnings reaches 230 (the remaining 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 abnormalities/warnings are saved as 231st abnormality/warning, 232nd abnormality/ warning ---. Each time the new abnormality/warning is saved, however, the HD465-7, HD605-7
abnormality/warning data are deleted from the oldest one. (The alarm of "2)" above is maintained.) 4. Integrated pay load/Total number of cycles data 1) If the total number of cycles reaches 9994 (the remaining capacity is 5 cycles or less) or the difference between the saved integrated pay load and 999900 tons (upper limit) becomes 5 times the rated hauling capacity, the following is repeated. H : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the total number of cycles reaches 9997 (the remaining capacity is 2 cycles or less) or the difference between the saved integrated pay load and 999900 tons (upper limit) becomes 5 times the rated hauling capacity, the following is repeated. H : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the total number of cycles reaches 9999 or the saved integrated pay load exceeds 999900 tons, both of the integrated pay load and total number of cycles are cleared to 0, and then they are integrated again. (The display unit displays the operating time normally again.) 5. For the method of resetting the data in 1 3 above when they become FULL, see "8.3 Operator check mode" in the instruction manual for Payload Meter (Card type). Once the data in 4 becomes FULL, it is not reset until it is cleared to 0 automatically. For the method of clearing this data to 0 forcibly before it becomes FULL, see "8.2 Forcible display of integrated pay load/total number of cycles" in the instruction manual for Payload Meter . 6. As for the order of display, any priority is not given to the items in 1 4 above. If multiple data become FULL simultaneously, they are displayed while the dump truck is not being loaded.
20-805
(1)
TROUBLESHOOTING
(*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, however.
20-806
(1)
HD465-7, HD605-7
TROUBLESHOOTING

Cause
HD465-7, HD605-7
20-807
(10)
TROUBLESHOOTING

20-808
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-1
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED
Action code Not set Failure code Controller code Not set Not set Trouble When starting switch is turned ON, any item is not displayed
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 Related information
Before performing the troubleshooting, check that fuse BT2 (12) circuit breaker (80 A) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R10 with normal one. 3) Turn the starting switch ON. When LC GDL relay (R10) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R10. 3) Check the relay. 1 LC GDL relay (R10) defective Between R10 (male) (5) (6) 1) Turn the starting switch OFF. 2) Disconnect connector R10. 3) Check the relay. 4) Apply voltage between R10 (male) (1) (2) Between R10 (male) (3) (5) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z No Yes Relay (R10) is normal Relay (R10) is defective
Do not apply 24 V beResistance Min. 1 M z tween (1) (2).
1) Turn the starting switch OFF. 2) Disconnect connector connectors R10 and fuse BT2 (12). 3) Connect T-adapter. Wiring harness between battery relay terminal Resistance Max. 1 z Disconnection in wiring har- M, fuse BT2 (12) R10 (female) (1), (5) ness Wiring harness between R10 (female) (2) 2 (Disconnection or defective Resistance Max. 1 z chassis ground contact) Wiring harness between PM5 (female) (1) Resistance Max. 1 z R10 (female) (3) Wiring harness between R10 (female) (13) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM5 (1) (13) Voltage 20 30 V Resistance Max. 1 z
3 Payload meter defective
HD465-7, HD605-7
20-809
(10)
TROUBLESHOOTING
LC-1
20-810
(1)
HD465-7, HD605-7
TROUBLESHOOTING
LC-2
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP
Action code Not set
Contents of trouble
After starting switch is turned ON, all external pilot lamps do not light up Trouble (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 shift lever in N and starting switch in ON.)
Action of controller None in particular. After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with Problem that 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), failure code "DF10KA" related to the transmission controller is displayed. Related information Before performing the troubleshooting, check that fuse BT2 (14) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) Cause 1 Breakage of bulb Standard value in normal state/Remarks on troubleshooting Any bulb must not be broken. 1) Turn the starting switch OFF. 2) Replace R40 with normal one. 3) Turn the starting switch ON. When payload meter relay (R40) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R40. 3) Check the relay. Between R40 (male) (5) (6) 2 Payload meter relay (R40) defective 1) Turn the starting switch OFF. 2) Disconnect connector R40. 3) Check the relay. 4) Apply voltage between R40 (male) (5) (6) Between R40 (male) (1) (2) Possible causes and standard value in normal state Apply 24 V between (5) (6). Resistance Max. 1 z Resistance 200 400 z No Yes Relay (R40) is normal Relay (R40) is defective
Do not apply 24 V beResistance Min. 1 M z tween (5) (6). Apply 24 V between (5) (6). Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, PM5, R43, R44, R45, B1, B2, and B3. 3) Connect T-adapter. 1) Any lamp does not light up. Wiring harness between SF1 (female) (4) R40 (female) (5) Resistance Max. 1 z Resistance Max. 1 z
Disconnection in wiring harWiring harness between R40 (female) (6) ness 3 (Disconnection or defective chassis ground contact) 2) Specific lamps do not light up.
Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z R43 (female) (3) Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z R44 (female) (3) Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z R45 (female) (3)
HD465-7, HD605-7
20-811
(10)
TROUBLESHOOTING
LC-2
Cause
Standard value in normal state/Remarks on troubleshooting Wiring harness between R43 (female) (6) G Resistance Max. 1 z (female) (1) Wiring harness between R44 (female) (6) A Resistance Max. 1 z (female) (1)
Wiring harness between R45 (female) (6) R Resistance Max. 1 z (female) (1) Wiring harness between B1 (female) (1) chassis ground Wiring harness between B2 (female) (1) chassis ground Wiring harness between B3 (female) (1) chassis ground Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, PM5, R43, R44, and R45. 3) Connect T-adapter. 1) Any lamp does not light up. aIn this case, fuse BT3 (10) (for supplying power to shift switch N) is broken. Possible causes and standard value in normal state 4 Ground fault in wiring harness Wiring harness between SF1 (female) (4) R40 (female) (5) 2) Specific lamps do not light up. Resistance between Wiring harness between PM5 (fe- PM5 (female) (4), R43 male) (4) R43 (female) (2) (female) (2) chassis ground Resistance between Wiring harness between PM5 (fe- PM5 (female) (5), R44 male) (5) R44 (female) (2) (female) (2) chassis ground Resistance between Wiring harness between PM5 (fe- PM5 (female) (6), R45 male) (6) R45 (female) (2) (female) (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM5 (4) (13) Between PM5 (5) (13) Between PM5 (6) (13) Voltage Voltage Voltage 20 30 V 20 30 V 20 30 V Max. 1 z Resistance between SF1 (female) (4), R40 Min. 1 M z (female) (5) chassis ground
Max. 1 z
Max. 1 z
20-812
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-2
HD465-7, HD605-7
20-813
(1)
TROUBLESHOOTING
LC-3
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET
Action code Not set Failure code Controller code Not set 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 Related information None in particular.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON. When payload meter lamp relays (R43), (R44), and (R45) is replaced with normal ones respectively, is failure repaired? No Yes Relays (R43), (R44), and (R45) are normal Relays (R43), (R44), and (R45) are defective
1) Turn the starting switch OFF. Payload meter lamp relays 2) Disconnect connectors R43, R44, and R45. 1 (R43), (R44), and (R45) de- 3) Check the relays. fective Between R43, R44, and R45 (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) (2). Between R43, R44, and R45 (3) (6). Apply 24 V between (1) (2). Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, R43, R44, and R45. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between SF1 (female) (4) R40 (female) (5) Voltage between SF1 (female) (4), R40 (female) (5) chassis ground
Max. 1 V
Voltage between PM5 Wiring harness between R40 (fe- (female) (4), R43 (female) (2), (4) R43 (female) (3) male) (2) chassis ground Voltage between PM5 Wiring harness between R40 (fe- (female) (4), R44 (female) (2), (4) R44 (female) (3) male) (2) chassis ground Voltage between PM5 Wiring harness between R40 (fe- (female) (4), R45 (female) (2), (4) R45 (female) (3) male) (2) chassis ground
Max. 1 V
Max. 1 V
Max. 1 V
20-814
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-3
HD465-7, HD605-7
20-815
(1)
TROUBLESHOOTING
LC-4
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL

Action code Not set Failure code Controller code Not set Not set 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.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON. 4) Set the shift lever in N. When payload meter lamp relays (R43), (R44), and (R45) is replaced with normal ones respectively, is failure repaired? No Yes Relays (R43), (R44), and (R45) are normal Relays (R43), (R44), 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. 3) Check the relays. fective Between R43, R44, and R45 (1) (2) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) (2). Between R43, R44, and R45 (3) (6). Possible causes and standard value in normal state Apply 24 V between (1) (2). Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors PM5, R43, R44, and R45. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between PM5 (female) (4) ness R43 (female) (2) 2 (Disconnection or defective Wiring harness between PM5 (female) (5) contact) R44 (female) (2) Wiring harness between PM5 (female) (6) R45 (female) (2) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors R40, R43, R44, R45, G, A, and R. 3) Connect T-adapter. Voltage between R43 Wiring harness between R43 (fe- (female) (6), G (female) (6) G (female) (1) male) (1) chassis ground 3 Hot short in wiring harness Voltage between R44 Wiring harness between R44 (fe- (female) (6), A (female) (6) A (female) (1) male) (1) chassis ground Voltage between R45 Wiring harness between R45 (fe- (female) (6), R (female) (6) R (female) (1) male) (1) chassis ground
Max. 1 V
Max. 1 V
Max. 1 V
20-816
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-4
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM5 (4) (13) Between PM5 (5) (13) Between PM5 (6) (13) Voltage Voltage Voltage 20 30 V 20 30 V 20 30 V
Possible causes and standard value 5 Payload meter defective in normal state
HD465-7, HD605-7
20-817
(10)
TROUBLESHOOTING
LC-5
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED)
Action code Not set Failure code Controller code Not set Not set Trouble Cycle data and engine ON/OFF data not recorded (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.) Action of controller None in particular. Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine Problem that appears on machine is stopped.)
Related information If the engine ON/OFF data are recorded, perform troubleshooting of LC-7.
Cause
1) Turn the starting switch OFF. 2) Disconnect connector PM5. Disconnection in wiring har- 3) Insert T-adapter. 4) Connect the connector. ness 1 (Disconnection or defective 5) Start the engine. 6) Depress the accelerator pedal more than "half". contact) Wiring harness between PM5 (fe- Voltage between PM5 male) (9) alternator terminal R (9) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Start the engine. 6) Depress the accelerator pedal more than "half". Between PM5 (9) chassis ground Voltage Min. 5 V Min. 5 V
20-818
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-6
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER "N" POSITION SIGNAL SYSTEM)
Action code Not set
Contents of trouble
Calibration cannot be performed and displayed clock does not Trouble conform to condition (Shift lever "N" position signal system)
Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N" 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.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R02 with normal one. 3) Turn the starting switch ON. When transmission neutral relay (R02) is replaced with normal one, is failure repaired? No Yes Relay (R02) is normal Relay (R02) is defective
Transmission neutral relay (R02) defective
1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. Between R02 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R02 (male) (1) (2). Between R02 (male) (3) (6) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z
Possible causes Disconnection in wiring har- Wiring harness between PM6 (female) (10) and standard value Resistance Max. 1 z ness R02 (female) (6) 2 in normal state (Disconnection or defective Wiring harness between SF1 (female) (4) contact) Resistance Max. 1 z R02 (female) (1) Wiring harness between R02 (female) (2), (3) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter. Ground fault in wiring harness Resistance between Wiring harness between PM6 (fe- PM6 (female) (10), male) (10) R02 (female) (6) R02 (female) (6) chassis ground Min. 1 M z
1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and R02. 3) Connect T-adapter.
Resistance between Wiring harness between SF1 (fe- SF1 (female) (4), R02 Min. 1 M z male) (4) R02 (female) (1) (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When shift lever is N Between PM6 (10) PM5 (13) When shift lever is not N Voltage Voltage 20 30 V Max. 1.5 V
HD465-7, HD605-7
20-819
(10)
TROUBLESHOOTING
LC-6
20-820
(1)
HD465-7, HD605-7
TROUBLESHOOTING
LC-7
LC-7 DISPLAYED LOGIC IS ABNORMAL

a) When loaded dump truck starts traveling, "0" is kept displayed. b) After loaded dump truck start traveling, display of odometer does not increase. c) When travel speed exceeds limit speed, "SP:SP" does not go off.
Action code Failure code Controller code Displayed logic is abnormal a) When loaded dump truck starts traveling, "0" is kept displayed. b) After loaded dump truck start traveling, display of odometer Trouble does not increase. c) When travel speed exceeds limit speed, "SP:SP" does not go off.
Not set
Not set
Not set
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. Action of controller None in particular.
Problem that After loaded dump truck start traveling, display of odometer does not increase. appears on machine
When loaded dump truck starts traveling, "0" is kept displayed.
When travel speed exceeds limit speed, "SP:SP" does not go off.
If the pay load is displayed during loading but "0" is displayed after the dump truck starts traveling until it dumps the load, the travel speed signal is not sensed. Related information If failure codes "DLT3KA" and "DLT3LC" related to transmission controller or failure codes "DLT3KA" and "dLT3LC" related to retarder controller are displayed, perform troubleshooting for them first. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and R02. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between PM5 (female) (7) (Disconnection or defective Possible causes CN5 (female) (1) contact) and standard value Wiring harness between PM5 (female) (8) in normal state CN5 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Connect T-adapter.
Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between PM5 (female) (7) (8) Resistance Max. 1 z
HD465-7, HD605-7
20-821
(10)
TROUBLESHOOTING
LC-7
d) Integrated pay load is not displayed.

Action code Not set Failure code Controller code Not set Not set Trouble Displayed logic is abnormal d) Integrated pay load is not displayed.
Contents of trouble Integrated pay load is not displayed.

Problem that Integrated pay load is not displayed. appears on machine
To display the integrated pay load, the following condition must be satisfied during the time from the start to the end of dumping. (1) When the load was dumped previous time, it was reduced to below 1/5 of the rated pay load within 5 minutes after the dump lever was changed from "LOWER" to "FLOAT". Related information (2) When the load was dumped previous time, "b-fl" was not displayed for 5 seconds just after the dump lever was changed from "LOWER" to "FLOAT". (3) The load to be dumped this time is above 1/2 of the rated pay load. If the payload meter displays "b-fl", perform troubleshooting of LC-8. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value 1 If the payload meter displays "b-FL", perform troubleshooting of LC-8. in normal state
20-822
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-7
e) Displayed and saved pay load is not correct.

Action code Not set Failure code Controller code Not set Not set Trouble Displayed logic is abnormal e) Displayed and saved pay load is not correct.
Contents of trouble Displayed and saved pay load is not correct.

Problem that Displayed and saved pay load is not correct. appears on machine
The error of the payload meter is 5%. The possible causes of display of wrong displayed and saved values are as follows (1) Defective setting of model selection switch of payload meter (2) Defective adjustment of suspension (3) Negligence of calibration of payload meter Related information <Precautions> i) If the load is dumped while the displayed pay load is changing because of pitching of the truck body, the saved value may become inaccurate. Accordingly, dump after the displayed value is fixed. ii) The pay load displayed in the loading place (just after loading) may be a little (1 - 5 t) less than that displayed in the dumping place. aFor details, see Operation Manual, 3. For higher accuracy. Cause Standard value in normal state/Remarks on troubleshooting LC display: "CO: X. X" 1 Wrong model setting X. X display HD465-7 0. 7 HD605-7 0. A
i) When truck is empty (1) Empty, (2) Flat place aSee STRUCTURE AND OPERATION, Service Check Mode, (b) Display of data for calculation of pay load. Possible causes and standard value in normal state 2 Improper suspension gas pressure Pressure difference between both sides (Front) 0.98 MPa {10 kg/cm2}
Pressure difference between both sides (Rear) 1.47 MPa {15 kg/cm2} If the pressure difference exceeds the above range, adjust the suspension gas, referring to "Testing and adjusting suspension cylinder". ii) When truck is loaded Contact (Interference) of frame stopper and rear axle housing iii)When truck turns on slope Contact (Interference) of frame stopper and rear axle housing 3 Improper calibration There must not be contact (Interference) There must not be contact (Interference)
Perform calibration according to the operation manual.
HD465-7, HD605-7
20-823
(10)
TROUBLESHOOTING
LC-8
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 Not set
Contents of trouble
Payload meter keeps displaying "b:FL" Trouble (Body "FLOAT" signal system: Dump lever is not in "FLOAT" position while truck is not dumping)
Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT" position while truck is not dumping)
Action of controller None in particular. Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT" Problem that appears on machine position while truck is not dumping)
Related information
Check that failure codes "DK52KX", "DK53L8", and "DK24KX" (failure in dump lever system) related to retarder controller are not displayed. If any of them is displayed, perform troubleshooting for it. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors PM6 and BRC1. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between PM6 (female) (9) contact) BRC1 (female) (15) 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and BRC1. 3) Connect T-adapter.
Resistance Max. 1 z
Resistance between Wiring harness between PM6 (fe- PM6 (female) (9), Min. 1 M z male) (9) BRC1 (female) (15) BRC1 (female) (15) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 3 Retarder controller defective 5) Turn the starting switch ON. Between BRC1 Dump lever is in "FLOAT". (15) chassis Dump lever is out of ground "FLOAT". 1) Turn the starting switch OFF. 2) Disconnect connector PM6. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM6 (9) chassis ground Dump lever is in "FLOAT". Dump lever is out of "FLOAT". Voltage Voltage 20 30 V Max. 1 V Voltage Voltage 20 30 V Max. 1 V
20-824
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-8
HD465-7, HD605-7
20-825
(1)
TROUBLESHOOTING
LC-9, LC-10
LC-9 PAYLOAD METER DISPLAYS "F:09" (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)
Action code Not set Failure code Controller code
Payload meter displays "F:09"
Not set
Trouble
Payload meter displays "F:09" (Lowering of internal backup battery voltage)
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 Related information None in particular.
Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard value Lowering of internal backup 1 Replace the internal backup battery according to the operation manual. in normal state battery voltage
LC-10 PAYLOAD METER DISPLAYS " :FULL" (DATA SAVING MEMORY IS FULL)
Payload meter displays " :FULL"
Not set
Trouble
Payload meter displays " :FULL" (Data saving memory is full)
Contents of trouble Payload meter displays "
:FULL". (Data saving memory is full.)

Problem that Payload meter displays " appears on machine Related information None in particular.
:FULL". (Data saving memory is full.)
Cause Cycle data saving memory 1 full a"L. FULL" is displayed Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Download the data to a personal computer and clear the memory to "0" (zero ) according to the operation manual.
Engine ON/OFF data saving Download the data to a personal computer and clear the memory to 2 memory full "0" (zero ) according to the operation manual. a"E. FULL" is displayed Failure and warning data 3 saving memory full a"F. FULL" is displayed Download the data to a personal computer and clear the memory to "0" (zero ) according to the operation manual.
Integrated pay load and total number of cycles data sav- Download the data to a personal computer and clear the memory to 4 ing memory full "0" (zero ) according to the operation manual. a"F. FULL" is displayed
20-826
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-11
LC-11 PAYLOAD METER DISPLAYS "F-20" : FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM
Payload meter displays "F-20"
Not set
LC-11 Payload meter displays "F-20" Trouble : Failure in power source of suspension pressure sensor and clinometer system
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. Pay load is not displayed correctly. Problem that appears on machine Operation data is not saved correctly.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, SURR, and PM3. 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) SUFL (female) (B) SUFL (female) (B) chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) SUFR (female) (B) SUFR (female) (B) chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) SURL (female) (B) SURL (female) (B) chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) SURR (female) (B) SURR (female) (B) chassis ground Min. 1 M z
Min. 1 M z
Min. 1 M z
Min. 1 M z
Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), PM3 Min. 1 M z male) (2) PM3 (female) (C) (female) (C) chassis ground 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, 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 Suspension pressure sensor 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 dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, 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 is replaced, the error is not corrected. normal.
HD465-7, HD605-7
20-827
(10)
TROUBLESHOOTING
LC-11
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON.
3 Clinometer sensor defective When the clinometer is replaced, the error is corrected. When the clinometer is replaced, the error is not corrected.
Clinometer is defective. Clinometer is normal.
1) Turn the starting switch OFF. 2) Disconnect connector PM6. 3) Connect T-adapter (only payload meter side). 4) Turn the starting switch ON. Between PM6 (male) (2) (3) Voltage 18 3 V
20-828
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-12
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"
Not set
Payload meter displays "F-21" "F-24" Trouble : Disconnection or grounding fault in suspension sensor signal system
Contents of trouble Input signal of suspension pressure sensor is below 1 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
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR. 3) Connect T-adapter. Wiring harness between PM6 (female) (2) SUFL (female) (B) Wiring harness between PM6 (female) (2) SUFR (female) (B) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between PM6 (female) (2) SURL (female) (B) Wiring harness between PM6 (female) (2) SURR (female) (B) Wiring harness between PM6 (female) (4) Disconnection in wiring har- SUFL (female) (C) ness Wiring harness between PM6 (female) (5) 1 (Disconnection or defective SUFR (female) (C) contact) Wiring harness between PM6 (female) (6) SURL (female) (C) Wiring harness between PM6 (female) (7) SURR (female) (C) Possible causes and standard value in normal state Wiring harness between PM6 (female) (3) SUFL (female) (A) Wiring harness between PM6 (female) (3) SUFR (female) (A) Wiring harness between PM6 (female) (3) SURL (female) (A) Wiring harness between PM6 (female) (3) SURR (female) (A)
1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (4), Min. 1 M z male) (4) SUFL (female) (C) SUFL (female) (C) chassis ground Ground fault in wiring har2 ness Resistance between Wiring harness between PM6 (fe- PM6 (female) (5), male) (5) SUFR (female) (C) SUFR (female) (C) chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (6), male) (6) SURL (female) (C) SURL (female) (C) chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (7), male) (7) SURR (female) (C) SURR (female) (C) chassis ground Min. 1 M z
Min. 1 M z
Min. 1 M z
HD465-7, HD605-7
20-829
(10)
TROUBLESHOOTING
LC-12
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, 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.
Suspension pressure sensor 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 dereplaced, the error is corrected. fective.
When rear left suspension pressure sensor is Rear left sensor is norreplaced, 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 is replaced, the error is not corrected. normal. 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. 4 Payload meter defective Between PM6 (2) (3) Between PM6 (4) (3) Between PM6 (5) (3) Between PM6 (6) (3) Between PM6 (7) (3) Voltage Voltage Voltage Voltage Voltage 18 3 V 15V 15V 15V 15V
20-830
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-12
HD465-7, HD605-7
20-831
(1)
TROUBLESHOOTING
LC-13
LC-13 PAYLOAD METER DISPLAYS "F-25" "F-28" : SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN SUSPENSION SENSOR SIGNAL SYSTEM
Payload meter displays "F-25" "F-28"
Not set
Payload meter displays "F-25" "F-28" Trouble : Short circuit with power source (Hot short) in suspension sensor signal system
Contents of trouble The suspension pressure input signal is above 5 V.

Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between PM6 Wiring harness between PM6 (fe- (female) (4), SUFL (feMax. 1 V male) (4) SUFL (female) (C) male) (C) and chassis ground Voltage between PM6 Wiring harness between PM6 (fe- (female) (5), SUFR Max. 1 V male) (5) SUFR (female) (C) (female) (C) and chassis ground Voltage between PM6 Wiring harness between PM6 (fe- (female) (6), SURL (feMax. 1 V male) (6) SURL (female) (C) male) (C) and chassis ground Voltage between PM6 Wiring harness between PM6 (fe- (female) (7), SURR Max. 1 V male) (7) SURR (female) (C) (female) (C) and chassis ground 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, 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.
Suspension pressure sensor 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 dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, 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 is Rear right sensor is replaced, the error is not corrected. normal.
20-832
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-13
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between PM6 (2) (3) Between PM6 (4) (3) Between PM6 (5) (3) Between PM6 (6) (3) Between PM6 (7) (3) Voltage Voltage Voltage Voltage Voltage 18 3 V 15V 15V 15V 15V
HD465-7, HD605-7
20-833
(10)
TROUBLESHOOTING
LC-14
LC-14 PAYLOAD METER DISPLAYS "F-CAL" (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)
Payload meter displays "F-CAL"
Not set
Trouble
Payload meter displays "F-CAL" (Negligence of calibration or internal damage of payload meter)
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 Related information None in particular.
Cause
Possible causes Negligence of calibration or and standard value internal damage of payload 1 Repair according to the operation manual. in normal state meter a"F-CAL" is displayed.
20-834
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-15
LC-15 PAYLOAD METER DISPLAYS "F:43" "F:45" (SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN EXTERNAL PILOT LAMP RELAY SYSTEM)
Action code Not set Failure code Controller code Not set Not set Trouble Payload meter displays "F:43" "F:45" (Short circuit with power source in external pilot lamp relay system)
Contents of trouble There is short circuit with power source (Hot short) in external pilot lamp relay system.
Action of controller None in particular. There is short circuit with power source (Hot short) in external pilot lamp relay system. Problem that appears on machine Payload meter displays "F:43" "F:45".
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON.
Relays (R43), (R44), When payload meter lamp relays No and (R45) are normal (R43), (R44), and (R45) is rePayload meter lamp relays placed with normal ones respecRelays (R43), (R44), Yes (R43), (R44), and (R45) de- tively, is failure repaired? and (R45) are defective fective 1) Turn the starting switch OFF. aWhen "F:43" is displayed, 2) Disconnect connectors R43, R44, and R45. 1 R43 is defective. 3) Check the relays. aWhen "F:44" is displayed, Resistance 200 400 z Between R43, R44, and R45 (1) (2) R44 is defective. aWhen "F:45" is displayed, 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. R45 is defective. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) (2). Between R43, R44, and R45 (3) (6). Apply 24 V between (1) (2). Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors PM5, R40, R43, R44, and R45. 3) Connect T-adapter. Hot short in wiring harness aWhen "F:43" is displayed, R43 system is short-circuited. aWhen "F:44" is displayed, 2 R44 system is short-circuited. aWhen "F:45" is displayed, R45 system is short-circuited. Voltage between PM5 Wiring harness between PM5 (fe- (female) (4), R43 (female) (4) R43 (female) (2) male) (2) chassis ground Voltage between PM5 Wiring harness between PM5 (fe- (female) (5), R44 (female) (5) R44 (female) (2) male) (2) chassis ground Voltage between PM5 Wiring harness between PM5 (fe- (female) (6), R45 (female) (6) R45 (female) (2) male) (2) chassis ground
Max. 1 V
Max. 1 V
Max. 1 V
HD465-7, HD605-7
20-835
(10)
TROUBLESHOOTING
LC-15
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R40, R43, R44, and R45. 3) Connect T-adapter. Voltage between PM5 Wiring harness between PM5 (fe- (female) (4), R43 (female) (4) R43 (female) (2) male) (2) chassis ground
Max. 1 V
Voltage between PM5 Wiring harness between PM5 (fe- (female) (5), R44 (female) (5) R44 (female) (2) male) (2) chassis ground Voltage between PM5 Wiring harness between PM5 (fe- (female) (6), R45 (female) (6) R45 (female) (2) male) (2) chassis ground
Max. 1 V
Max. 1 V
Payload meter defective aWhen "F:43" is displayed, PM5 (4) system is defective. aWhen "F:44" is displayed, 4 PM5 (5) system is defective. aWhen "F:45" is displayed, PM5 (6) system is defective.
1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM 5 (4) (13) Between PM 5 (5) (13) Between PM 5 (6) (13) Voltage Voltage Voltage 20 30 V 20 30 V 20 30 V
20-836
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-16
LC-16 PAYLOAD METER DISPLAYS "L-bad" (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)
Action code Not set Failure code Controller code Not set Not set Trouble Payload meter displays "L-bad" (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. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5, PM6, SUFL, SUFR, SURL, and SURR. 3) Connect T-adapter. Wiring harness between PM5 (female) (13) Resistance Max. 1 z SUFR (female) (A) Disconnection in wiring har- Wiring harness between PM6 (female) (4) ness SUFL (female) (C) 1 (Disconnection or defective Wiring harness between PM6 (female) (5) contact) SUFR (female) (C) Wiring harness between PM6 (female) (6) SURL (female) (C) Wiring harness between PM6 (female) (7) SURR (female) (C) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, 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 Suspension pressure sensor 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 dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, 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 is Rear right sensor is replaced, the error is not corrected. normal. Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
HD465-7, HD605-7
20-837
(10)
TROUBLESHOOTING
LC-16
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between PM6 (2) (3) Between PM6 (4) (3) Between PM6 (5) (3) Between PM6 (6) (3) Between PM6 (7) (3) Voltage Voltage Voltage Voltage Voltage 18 3 V 15V 15V 15V 15V
20-838
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-17
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 Not set
Contents of trouble
External pilot lamp indicates forecast while truck is not being Trouble loaded or clock is displayed while truck travels for 160 m after it is loaded
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 of controller None in particular. External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck Problem that appears on machine travels for 160 m after it is loaded
Possible causes Cause and standard value 1 Improper calibration in normal state
Standard value in normal state/Remarks on troubleshooting Perform calibration according to the operation manual.
HD465-7, HD605-7
20-839
(10)
TROUBLESHOOTING
LC-18
LC-18 PAYLOAD METER DISPLAYS "F-31" : GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM
Not set
Payload meter displays "F-31" Trouble : Grounding fault or disconnection in clinometer sensor signal system
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 phenomenon does not indicate a failure) and the clinometer is installed normally. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between PM6 (female) (8) ness PM3 (female) (B) 1 (Disconnection or defective Wiring harness between PM6 (female) (2) contact) PM3 (female) (C) Wiring harness between PM6 (female) (3) PM3 (female) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (8), PM3 Min. 1 M z male) (8) PM3 (female) (B) (female) (B) chassis ground 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. 3 Clinometer sensor defective When the clinometer is replaced, error is cor- Clinometer is defecrected. tive. When the clinometer is replaced, error is not corrected. 1) Turn the starting switch OFF. 2) Disconnect connector PM6. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM6 (2) (3) Between PM6 (8) (3) Voltage Voltage 18 3 V 1.6 3.6 V Clinometer is normal. Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
20-840
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-18
HD465-7, HD605-7
20-841
(1)
TROUBLESHOOTING
LC-19
LC-19 PAYLOAD METER DISPLAYS "F-32" : SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM
Not set
Trouble Payload meter 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 phenomenon does not indicate a failure) and the clinometer is installed normally. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between PM6 Wiring harness between PM6 (fe- (female) (8), PM3 (female) (8) PM3 (female) (B) male) (B) chassis ground
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector PM3. Possible causes 3) Insert T-adapter. and standard value in normal state 2 Clinometer sensor defective 4) Connect the connector. 5) Turn the starting switch ON. Between PM3 (C) (A) Between PM3 (B) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between PM6 (2) PM5 (13) Between PM6 (8) PM5 (13) Voltage Voltage 18 3 V 1.6 3.6 V Voltage Voltage 18 3 V 1.6 3.6 V
20-842
(10)
HD465-7, HD605-7
TROUBLESHOOTING
LC-19
HD465-7, HD605-7
20-843
(1)
TROUBLESHOOTING
LC-20
LC-20 PAYLOAD METER DISPLAYS "F:18" (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)
Action code Not set Failure code Controller code Not set Not set Trouble Payload meter displays "F:18" (Disconnection in charge level signal system)
Contents of trouble There is disconnection in the charge level signal system.
Action of controller None in particular. There is disconnection in the charge level signal system. Problem that appears on machine Payload meter displays "F:18".
Related information
If failure code "AB00MA" (Malfunction of alternator) related to transmission controller is displayed, perform troubleshooting for it first. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connector PM5. Disconnection in wiring har- 3) Insert T-adapter. 4) Connect the connector. ness 1 (Disconnection or defective 5) Start the engine. 6) Depress the accelerator pedal more than "half". contact) Wiring harness between PM5 (fe- Voltage between PM5 male) (9) alternator terminal R (9) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Start the engine. 6) Depress the accelerator pedal more than "half". Between PM5 (9) chassis ground Voltage Min. 5 V Min. 5 V
20-844
(10)
HD465-7, HD605-7
TROUBLESHOOTING FOR MONITOR SYSTEM (MON MODE)
Electrical system diagram related to monitor .............................................................................................. 20-904 Information in troubleshooting table........................................................................................................ 20-905 Phenomenon code table ......................................................................................................................... 20-906 [B@C7NS] Rear brake oil: overheating (NS) ........................................................................................ 20-907 [B@CENS] Torque converter: overheating (NS) ................................................................................... 20-907 [DAF0KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-908 [DAF9KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-911 [DAFSKQ] Monitor panel: disagreement of model selection signals (KQ) ........................................... 20-912 [DAQSKR] S-NET communication defective (between transmission controller and machine monitor) (KR)............................................ 20-913 [DASRKR] CAN communication/Communication defective: abnormality in objective component (KR) .... 20-916 [DB1SKR] S-NET communication defective (between retarder controller and machine monitor) (KR)..... 20-918 [DV00KB] Short circuit in alarm buzzer output: short circuit (KB) ....................................................... 20-921 MON- 1 When starting switch is turned ON, machine monitor does not display any item ............... 20-922 MON- 2 When starting switch is turned OFF and machine monitor does not operate normally ...... 20-923 MON- 3 Alarm buzzer defective ....................................................................................................... 20-925 a) Alarm buzzer does not sound ....................................................................................... 20-925 b) Alarm buzzer does not stop sounding........................................................................... 20-926 MON- 4 Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal ...................................................................................................................... 20-927 a) Items displayed by gauges are different from machine condition ................................. 20-927 b) Items displayed by warning lamps are different from machine condition ...................... 20-928 c) Character display does not display any item or it displays abnormally ......................... 20-928 MON- 5 Operation of machine monitor cannot be checked normally .............................................. 20-929 MON- 6 Display of character display cannot be selected normally.................................................. 20-930 a) Machine monitor mode select switch 1 system is abnormal ......................................... 20-930 b) Machine monitor mode select switch 2 system is abnormal ......................................... 20-932 MON- 7 Power mode select function does not work normally ......................................................... 20-934 MON- 8 Seat belt warning lamp does not operate normally ............................................................ 20-935 a) Lamp lights up while seat belt is fastened..................................................................... 20-935 b) Lamp does not light up while seat belt is unfastened.................................................... 20-936 MON- 9 Turn signals and hazard lamp do not operate normally...................................................... 20-937 a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash................................................................................................................ 20-937 b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up ................................................................................................. 20-938 c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash (When hazard lamp switch is operated, however, turn signal lamps flash normally) ......... 20-939 d) When hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-940 e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-942 f) Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however) ................................................................. 20-943
HD465-7, HD605-7
20-901
(10)
MON-10
MON-11
MON-12
Night lighting is abnormal ................................................................................................... 20-945 a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up. .................................................................................. 20-945 b) When lamp switch is set in 1st position, small lamp and night lamp do not light up ..... 20-946 c) When lamp switch is OFF, small lamp and night lamp light up ..................................... 20-947 d) When dimmer switch is operated, brightness of night lighting does not change........... 20-948 e) Head lamp "Hi" beam does not light up ........................................................................ 20-949 f) Head lamp "Lo" beam does not light up........................................................................ 20-950 g) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-951 h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-952 Power window does not operate normally.......................................................................... 20-954 a) Operating left side does not .......................................................................................... 20-954 b) Operating right side does not ........................................................................................ 20-955 Defective air conditioner ..................................................................................................... 20-957 a) Air conditioner does not operate ................................................................................... 20-957 b) Air does not come out or air flow cannot be adjusted ................................................... 20-958 c) Air is not cooled or temperature cannot be adjusted (Electric system) ......................... 20-960 d) Recirculated air and fresh air cannot be selected ......................................................... 20-962 e) Air outlets cannot be selected ....................................................................................... 20-963 f) Air is not cooled (Mechanical system)........................................................................... 20-965 g) Air is not heated (Defective hot water circuit)................................................................ 20-966 h) Abnormal sound comes out .......................................................................................... 20-966 i) Water leaks ................................................................................................................... 20-967
a For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM Mode).
20-902
(5)
HD465-7, HD605-7
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

20-904
(2)
HD465-7, HD605-7
TROUBLESHOOTING

Cause
HD465-7, HD605-7
20-905
(10)
TROUBLESHOOTING

20-906
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[B@C7NS], [B@CENS]
[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS)

Action code E02 Failure code Controller code B@C7NS MON Trouble Rear brake oil: Overheating (NS) (Brake cooling oil overheating)
Contents of trouble Brake cooling oil is overheating.

Problem that If the machine is used without repairing, the rear brake may be broken. appears on machine Related information This failure code is displayed when possibility of occurrence of a failure in the electric system is low.
Cause Possible causes Overheating of brake cool1 and standard value ing oil in normal state 2 Machine monitor defective
If the brake cooling oil is not overheating, the machine monitor is defective.
[B@CENS] TORQUE CONVERTER: OVERHEATING (NS)

Action code E02 Failure code Controller code B@CENS MON Trouble Torque converter: Overheating (NS)
Contents of trouble Torque converter is overheating

Problem that If the machine is used without repairing, the torque may be broken. appears on machine Related information This failure code is displayed when possibility of occurrence of a failure in the electric system is low.
Cause Possible causes Overheating of torque con1 and standard value verter in normal state 2 Machine monitor defective
If the torque converter is not overheating, the machine monitor is defective.
HD465-7, HD605-7
20-907
(10)
TROUBLESHOOTING
[DAF0KM]
[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)

Action code E03
Contents of trouble
Failure code Controller code Monitor panel: Mistake in operation or setting (KM) Trouble (Disagreement of optional settings) DAF0KM MON The optional settings of the rotary switch and dip switch on the rear side of the machine monitor do not agree with the signals of the optional setting connector.
The controller maintains the abnormal state until the starting switch is turned OFF. The controller does not recognize the functions (If equipped), the settings of which do not agree the Action of controller signals. The controller does not record this failure in the fault history.
Problem that Some functions (If equipped) do not work. appears on machine
Connections of wiring harnesses OP1OP7 depend on the specification. For details, see "Adjustment of machine monitor". This failure can be checked with SW13 (monitor code: 30800), SW51, 52 (monitor code: 30900), Related information SW53, 54 (monitor code: 30901), SW61, 62 (monitor code: 30902), SW63, and 64 (monitor code: 30903) on the rear side of the machine monitor. This failure can be checked with optional selection connectors OP1, 2 (monitor code: 31000), OP3, 4 (monitor code: 31001), and OP5, 6 (monitor code: 31002). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter. When connected Wiring harness (CLOSED) between DPC3A (female) (4) When disconOP1 (female) (1) nected (OPENED) Resistance between DPC3A (female) (4) Max. 1 z chassis ground Resistance between DPC3A (female) (4) Min. 1 M z chassis ground Resistance between When connected DPC3A (female) (6) Max. 1 z Wiring harness (CLOSED) chassis ground between DPC3A (female) (6) Resistance between When disconOP2 (female) (1) nected DPC3A (female) (6) Min. 1 M z (OPENED) chassis ground When connected Wiring harness (CLOSED) between DPC3A (female) (7) When disconOP3 (female) (1) nected (OPENED) Resistance between DPC3A (female) (7) chassis ground Max. 1 z
Resistance between DPC3A (female) (7) chassis ground Resistance between When connected DPC3A (female) (13) Wiring harness (CLOSED) chassis ground between DPC3A (female) (13) When disconResistance between OP4 (female) (1) nected DPC3A (female) ((13) (OPENED) chassis ground Resistance between When connected DPC3A (female) (14) Wiring harness (CLOSED) chassis ground between DPC3A (female) (14) When disconResistance between OP5 (female) (1) nected DPC3A (female) (14) (OPENED) chassis ground
Min. 1 M z
Max. 1 z
Min. 1 M z
Max. 1 z
Min. 1 M z
20-908
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DAF0KM]
Cause
Standard value in normal state/Remarks on troubleshooting When connected Wiring harness (CLOSED) between DPC3A (female) (15) When disconOP6 (female) (1) nected (OPENED) Resistance between DPC3A (female) (15) Max. 1 z chassis ground Resistance between DPC3A (female) (15) Min. 1 M z chassis ground Max. 1 z
Resistance between When connected DPC3A (female) (16) Wiring harness (CLOSED) chassis ground between DPC3A (female) (16) When disconResistance between OP7 (female) (1) nected DPC3A (female) (16) (OPENED) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter. When connected Resistance Resistance between (CLOSED) DPC3A (female) (4) When disconnected chassis ground Resistance (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (6) When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (7) When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (13) When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (14) When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (15) When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (16) When disconnected chassis ground (OPENED)
Min. 1 M z
Max. 1 z Min. 1 M z
Resistance Max. 1 z Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z
HD465-7, HD605-7
20-909
(10)
TROUBLESHOOTING
[DAF0KM]
20-910
(1)
HD465-7, HD605-7
TROUBLESHOOTING
[DAF9KM]
[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)

Action code E03 Failure code Controller code DAF9KM MON Trouble Monitor panel: Mistake in operation or setting (KM) (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 maintains the abnormal state until the starting switch is turned OFF. The controller does not record this failure in the fault history. The machine monitor mode select switch does not work. The head lamp HIGH pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.
Problem that The optional functions do not work. appears on machine Related information None in particular.
Standard value in normal state/Remarks on troubleshooting The connector check signal connectors are connected normally. aConnector check signal connectors: DPC3A (5) (OPEN), DPC2A (5) (CLOSE)
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector DPC2A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between fuse terminal BT4 (2) contact) Resistance Max. 1 z DPC2A (female) (5) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter.
Ground fault in wiring har3 ness Wiring harness between DPC3A (female) (5) Resistance Min. 1 M z (Grounding fault of terminal) chassis ground aThis must not occur basically, since the wiring harness is not connected. 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Connect T-adapter. Resistance between DPC2A (female) (5) chassis ground Resistance Min. 1 M z
HD465-7, HD605-7
20-911
(10)
TROUBLESHOOTING
[DAFSKQ]
[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)

Action code E03
Contents of trouble
Failure code Controller code DAFSKQ MON
Trouble Monitor panel: Disagreement of model selection signals (KQ)
Since communication with the transmission controller (S-NET) is defective, model selection information cannot be received or the rotary switch of the transmission controller is not set normally. The controller maintains the abnormal state until the starting switch is turned OFF. The controller controls the truck as HD465-7.
None of the meters and gauges display. Problem that appears on machine Some panel switches and lamps do not work.
Related information If another failure code "DAQAKQ" is displayed, perform troubleshooting for it.
Cause 1 Communication circuit defective
Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for "DAQSKR". aIf the failure is not repaired by replacing the machine monitor, the machine monitor is defective. aWhen replacing the machine monitor, see TESTING AND ADJUSTING, Adjustment of machine monitor.
Possible causes and standard value 2 Machine monitor defective in normal state
Transmission controller de- aIf the failure is not repaired by replacing the machine monitor, the fective transmission controller is defective.
20-912
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQSKR]
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR)
Action code E03 Failure code Controller code DAQSKR MON Trouble S-NET communication defective (KR) (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. The meters, gauges, warning lamps, and special functions that obtain information from the transmisProblem that appears on machine sion controller do not operate or display.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG. 3) Connect T-adapter. Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z Between each couple of JCD (male) terminals Resistance Max. 1 z Between each couple of JCE (male) terminals Resistance Max. 1 z Between each couple of JCF (male) terminals Resistance Max. 1 z Between each couple of JCG (male) terminals Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. Wiring harness between DPC4 (female) (1) Resistance Max. 1 z ATC4 (female) (12) Wiring harness between DPC4 (female) (2) Resistance Max. 1 z Disconnection in wiring har- ATC4 (female) (6) ness 2 (Disconnection or defective Wiring harness between DPC4 (female) (4) Resistance Max. 1 z ATC4 (female) (10) contact) Wiring harness between DPC4 (female) (5) Resistance Max. 1 z ATC4 (female) (10) aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 3 Ground fault in wiring harness Between DPC4 (female) (1), (2) chassis ground Resistance Min. 1 M z
aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 4) Turn the starting switch ON.
Between DPC4 (female) (1), (2) chassis ground
Voltage
Max. 1 V
aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted.
HD465-7, HD605-7
20-913
(10)
TROUBLESHOOTING
[DAQSKR]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC4. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage Voltage 69V 69V
Possible causes and standard value Transmission controller de- Between ATC4 (6) (10) 5 in normal state fective Between ATC4 (12) (10)
aIf any other controller does not have an error in S-NET communication, disconnect only the S-NET signal output of the transmission controller and check that the transmission controller is outputting the normal voltage.
20-914
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DAQSKR]
HD465-7, HD605-7
20-915
(2)
TROUBLESHOOTING
[DASRKR]
[DASRKR] CAN COMMUNICATION/COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR)

Action code E03 Failure code Controller code DASRKR MON CAN communication/Communication defective: Abnormality in Trouble objective component (KR) (Between engine controller and machine monitor)
Contents of trouble Communication (CAN) information cannot be obtained from the engine controller.
Action of controller The controller maintains the condition at the time when the failure occurs.
Problem that The meters, gauges, warning lamps, and special functions that obtain information from the engine conappears on machine troller do not operate or display. Related information
Cause
1) Turn the starting switch OFF. 2) Disconnect connector JC14. 1 Junction connector defective 3) Connect T-adapter. Between JC14 (male) (2) (8) Between JC14 (male) (4) (6) 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4 and ECMB. 3) Connect T-adapter.
2 Wiring harness defective
Wiring harness between DPC4 (female) (3) Resistance 40 80 z DPC4 (female) (8) aCheck that terminal resistors CAN and CAN2 are connected. The resistance of each terminal resistor is 120 z. aCheck that a personal computer or a controller is not connected to CAN1. aIf VHMS is connected, disconnect it. 1) Turn the starting switch OFF. 2) Replace the engine controller. 3) Turn the starting switch ON.
When the engine controller is replaced, does communication become normal? 1) Turn the starting switch OFF. 2) Replace the machine monitor. 3) Turn the starting switch ON.
No Yes
Engine controller is normal. Engine controller is defective.
When the machine monitor is replaced, does communication become normal?
No Yes
Machine monitor is normal. Machine monitor is defective
aWhen replacing the machine monitor, see TESTING AND ADJUSTING, Adjustment of machine monitor.
20-916
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DASRKR]
HD465-7, HD605-7
20-917
(1)
TROUBLESHOOTING
[DB1SKR]
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR)
Action code E03 Failure code Controller code DB1SKR MON Trouble S-NET communication defective (KR) (Between retarder controller and machine monitor)
Contents of trouble Communication (S-NET) information cannot be obtained from the retarder controller.
Action of controller The controller maintains the condition at the time when the failure occurs. The meters, gauges, warning lamps, and special functions that obtain information from the retarder Problem that appears on machine controller do not operate or display.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG. 3) Connect T-adapter. Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z Between each couple of JCD (male) terminals Resistance Max. 1 z Between each couple of JCE (male) terminals Resistance Max. 1 z Between each couple of JCF (male) terminals Resistance Max. 1 z Between each couple of JCG (male) terminals Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. Wiring harness between DPC4 (female) (1) Resistance Max. 1 z BRC4 (female) (12) Wiring harness between DPC4 (female) (2) Resistance Max. 1 z Disconnection in wiring har- BRC4 (female) (6) ness 2 (Disconnection or defective Wiring harness between DPC4 (female) (4) Resistance Max. 1 z BRC4 (female) (10) contact) Wiring harness between DPC4 (female) (5) Resistance Max. 1 z BRC4 (female) (10) aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 3 Ground fault in wiring harness Between DPC4 (female) (1), (2) chassis ground Resistance Min. 1 M z
aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 4) Turn the starting switch ON.
Between DPC4 (female) (1), (2) chassis ground
Voltage
Max. 1 V
aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted.
20-918
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DB1SKR]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC4. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Voltage Voltage 69V 69V
Possible causes and standard value 5 Retarder controller defective Between BRC4 (6) (10) in normal state Between BRC4 (12) (10)
aIf any other controller does not have an error in S-NET communication, disconnect only the S-NET signal output of the retarder controller and check that the retarder controller is outputting the normal voltage.
HD465-7, HD605-7
20-919
(10)
TROUBLESHOOTING
[DB1SKR]
20-920
(2)
HD465-7, HD605-7
TROUBLESHOOTING
[DV00KB]
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT: SHORT CIRCUIT (KB)

Action code E01 Failure code Controller code DV00KB MON Trouble Short circuit in alarm buzzer output: Short circuit (KB)
Contents of trouble There is short circuit with the power source in the output circuit of the alarm buzzer.
The controller maintains the abnormal state until the starting switch is turned OFF. The controller turns the output circuit of the alarm buzzer OFF.
Problem that The alarm buzzer does not sound. appears on machine Related information None in particular.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors DPC1 and BZ2. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between DPC1 (female) (13) BZ2 (female) (2) Voltage between DPC1 (female) (13), BZ2 (female) (2) chassis ground
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector BZ2 (2) and remove the buzzer. 3) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2 (male) (2). 2 Alarm buzzer defective The alarm buzzer sounds. The alarm buzzer does not sound. aCheck the alarm buzzer unit. 3 Machine monitor defective If the results of 1) and 2) above are normal, the machine monitor is defective. Alarm buzzer is normal. Alarm buzzer is defective.
HD465-7, HD605-7
20-921
(10)
TROUBLESHOOTING
MON-1
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM
Action code Not set Failure code Controller code Not set MON Trouble When starting switch is turned ON, machine monitor does not 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
Failure code is not displayed.

Related information Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not
broken. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. Disconnection in wiring har- Wiring harness between battery ness relay B fuse BT2 (1) 1 (Disconnection or defective Wiring harness between fuse BT2 contact) (2) DPC1 (female) (6), (7) Possible causes and standard value in normal state Voltage between BT2 20 30 V (1) and chassis ground Voltage between DPC1 (6), (7) and chassis ground 20 30 V
1) Turn the starting switch OFF. 2) Disconnect connectors DPC4 and BRC4. 3) Connect T-adapter. Wiring harness between DPC1 (9), (10) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON. Between DPC1(6), (7) (9), (10) Voltage 20 30 V Resistance Max. 1 z
20-922
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-2
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY
Action code Not set Failure code Controller code Not set MON Trouble When starting switch is turned OFF and machine monitor does 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. Action of controller None in particular. When the starting switch is turned OFF and the machine monitor mode select switch is operated, the service meter and odometer are not displayed. Problem that appears on machine When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not turned on. Failure code is not displayed. Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not Related information broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) Cause Standard value in normal state/Remarks on troubleshooting When the starting switch is turned Main power source (SW power ON, the machine monitor operates source) is normal. normally. 1 Main power source (SW power source) defective Even if the starting switch is turned Main power source (SW power ON, the machine monitor does not source) is defective. operate normally. aIf the main power source (SW power source) is defective, perform troubleshooting of MON-1. 1) Turn the starting switch OFF. Disconnection in wiring har- Wiring harness between J01 (feness male) (Y) fuse BT2 (21) Possible causes 2 (Disconnection or defective and standard value Wiring harness between fuse BT2 contact) in normal state (22) DPC1 (female) (4), (5) Voltage between BT2 (21) chassis ground Voltage between DPC1 (4), (5) chassis ground 20 30 V
20 30 V
Hazard lamp switch, related 3 wiring harness, or related re- aReferring to MON-9 d), perform troubleshooting. lay defective Machine monitor mode se4 lect switch 1 or related wiring aReferring to MON-6, perform troubleshooting. harness defective 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. aKeep the starting switch OFF. Between DPC1 (4), (5) (9), (10) Voltage 20 30 V
HD465-7, HD605-7
20-923
(10)
TROUBLESHOOTING
MON-2
20-924
(1)
HD465-7, HD605-7
TROUBLESHOOTING
MON-3
MON-3 ALARM BUZZER DEFECTIVE

a) Alarm buzzer does not sound
Alarm buzzer defective Trouble a) Alarm buzzer does not sound Not set MON 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. Action of controller None in particular. Not set
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.
Action code
Failure code is not displayed. If failure code "DV00KB" is displayed, perform troubleshooting for it. Related information Before performing troubleshooting, check that the fuse is not broken and the voltage between BZ2 and chassis ground is 20 30 V when the starting switch is ON. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connectors BZ2 and battery BT4 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between fuse BT4 (2) BZ2 Resistance Max. 1 z (Disconnection or defective (female) (1) contact) Wiring harness between BZ2 (female) (2) Resistance Max. 1 z DPC (female) (13) 1) Turn the starting switch ON. 2) Connect BZ2 (2) to the chassis ground. The alarm buzzer sounds. Alarm buzzer is normal. The alarm buzzer does not sound. 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON. 3 Machine monitor defective Alarm buzzer is defective.
2 Alarm buzzer defective
Under the condition for turning the Voltage between alarm buzzer ON DPC1 (13) (9), (10) Under the condition for turning the Voltage between alarm buzzer OFF DPC1 (13) (9), (10)
Max. 1 V 20 30 V
aThe condition for turning the alarm buzzer ON is that the starting switch is ON, an emergency stop item lights up, the centralized warning lamps light up, etc.
HD465-7, HD605-7
20-925
(10)
TROUBLESHOOTING
MON-3
b) Alarm buzzer does not stop sounding

Action code Not set
Contents of trouble
Failure code Controller code Not set MON
Trouble
Alarm buzzer defective 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 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
Failure code is not displayed. If failure code "DV00KB" is displayed, perform troubleshooting for it. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BZ2 and battery BT4 terminal (2). 3) Connect T-adapter. 1 Short circuit in wiring harness Resistance between wiring harness between fuse BT4 (2) BZ2 (female) (1) and wiring harness between DPC1 (fe- Min. 1 M z male) (13) BZ2 (female) (2) Wiring harness between BZ2 (female) (2) DPC (female) (13) 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON. 2 Machine monitor defective Under the condition for turning the Voltage between alarm buzzer ON DPC1 (13) (9), (10) Under the condition for turning the Voltage between alarm buzzer OFF DPC1 (13) (9), (10) Max. 1 V 20 30 V Resistance Max. 1 z
aThe condition for turning the alarm buzzer ON is that the starting switch is ON, an emergency stop item lights up, the centralized warning lamps light up, etc.
20-926
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-4
MON-4 ITEMS DISPLAYED BY GAUGES, WARNING LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL
a) Items displayed by gauges are different from machine condition
Action code Not set
Contents of trouble
Items displayed by gauges, warning lamps, and character disTrouble play of machine monitor are abnormal a) Items displayed by gauges are different from machine condition
The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The items displayed by the gauges are different from the machine condition.)

Problem that The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The items displayed by the gauges are different from the machine condition.) Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. 2) Operate the machine monitor.
If the inputting condition of the related sensor Sensor signal system signal is monitored, the gauges display noris normal. Sensor signal system defec- mally. 1 tive If the inputting condition of the related sensor Sensor signal system Possible causes signal is monitored, the gauges do not display is defective. and standard value normally. in normal state aIf the sensor signal system is defective, perform troubleshooting for each related signal system. 1) Turn the starting switch ON. 2 Machine monitor defective If the machine monitor check switch is operat- Machine monitor is ed, the gauges display normally. normal. If the machine monitor check switch is operat- Machine monitor is deed, the gauges do not display normally. fective.
HD465-7, HD605-7
20-927
(10)
TROUBLESHOOTING
MON-4
b) Items displayed by warning lamps are different from machine condition

Action code Not set
Contents of trouble
Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal Trouble b) Items displayed by warning lamps are different from machine condition
The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The items displayed by the warning lamps are different from the machine condition.)

Problem that The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The items displayed by the warning lamps are different from the machine condition.) Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. 2) Operate the machine monitor. If the inputting condition of the related sensor Switch or sensor sigsignal is monitored, the gauges display nornal system is normal. mally.
Switch or sensor signal sys- If the inputting condition of the related sensor Switch or sensor sigtem defective signal is monitored, the gauges do not display nal system is defecnormally. tive. aIf the switch or sensor signal system is defective, perform troubleshooting for each related signal system. (See troubleshooting for the controllers to which the related sensor signals are input.) 1) Turn the starting switch ON. If the machine monitor check switch is operat- Machine monitor is ed, the lamps display normally. normal. If the machine monitor check switch is operat- Machine monitor is deed, the lamps do not display normally. fective.
c) Character display does not display any item or it displays abnormally

Action code Not set
Contents of trouble
Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal Trouble c) Character display does not display any item or it displays abnormally
The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The character display does not display any item or it displays abnormally.)

Problem that The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The character display does not display any item or it displays abnormally.) Related information Failure code is not displayed.
Cause Possible causes and standard value 1 Machine monitor defective in normal state
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. If the machine monitor check switch is operat- Machine monitor is ed, the character display displays normally. normal. If the machine monitor check switch is operatMachine monitor is deed, the character display does not display norfective. mally.
20-928
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-5
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY

Action code Not set
Contents of trouble
Trouble Operation of machine monitor cannot be checked normally
When the machine monitor check switch is operated, any of the lamps and gauges does not display. 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. Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CK1. 3) Check the switch
Machine monitor check switch defective
Between CK1 (male) (3) (6)
Operate (Press) the machine monResistance Max. 1 z itor check switch. Do not operate (Release) the maResistance Min. 1 M z chine monitor check switch.
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CK1, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. ness Possible causes 2 Wiring harness between fuse BT2 (2) CK1 Resistance Max. 1 z (Disconnection or defective and standard value (female) (3) contact) in normal state Wiring harness between DPC2A (female) (10) Resistance Max. 1 z CK1 (female) (6) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2A (10) chassis ground Operate (Press) the machine monitor check switch. Do not operate (Release) the machine monitor check switch. Voltage Voltage 20 30 V Max. 1 V
HD465-7, HD605-7
20-929
(10)
TROUBLESHOOTING
MON-6
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY

a) Machine monitor mode select switch 1 system is abnormal
Action code Not set
Contents of trouble
Failure code Controller code Display of character display cannot be selected normally Trouble a) Machine monitor mode select switch 1 system is abnormal Not set MON
Display of the character display cannot be selected normally. (Machine monitor mode select switch 1 system is abnormal.) Action of controller None in particular.
Problem that Display of the character display cannot be selected normally. (Machine monitor mode select switch 1 appears on machine system is abnormal.) Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CH1. 3) Check the switch.
Machine monitor mode se1 lect switch 1 system defective
Between CH1 (male) (2) (3) Between CH1 (male) (1) (3)
Press [ ] of the machine monitor Resistance Max. 1 z select switch 1. Set the machine monitor select switch in NEUTRAL. Resistance Min. 1 M z
Set the machine monitor select Resistance Min. 1 M z switch in NEUTRAL. Press [ ] of the machine monitor Resistance Max. 1 z select switch 1. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CH1, and fuse BT2 terminal (22). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (22) CH1 Resistance Max. 1 z ness (female) (3) 2 (Disconnection or defective Wiring harness between DPC2A (female) (8) contact) Resistance Max. 1 z CH1 (female) (2) Wiring harness between DPC2A (female) (14) Resistance Max. 1 z CH1 (female) (1) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A and CH1. 3) Connect T-adapter. Voltage between Wiring harness between DPC2A DPC2A (female) (8), (female) (8) CH1 (female) (2) CH1 (female) (2) chassis ground Wiring harness between DPC2A (female) (14) CH1 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2A (8) chassis ground Between DPC2A (14) chassis ground Press [ ] of the machine monitor select switch 1. Set the machine monitor select switch in NEUTRAL. Set the machine monitor select switch in NEUTRAL. Press [ ] of the machine monitor select switch 1. Voltage Voltage Voltage Voltage 20 30 V Max. 1 V Max. 1 V 20 30 V Voltage between DPC2A (female) (14), CH1 (female) (1) chassis ground
Max. 1 V
Max. 1 V
20-930
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-6
HD465-7, HD605-7
20-931
(1)
TROUBLESHOOTING
MON-6
b) Machine monitor mode select switch 2 system is abnormal

Display of character display cannot be selected normally Trouble a) Machine monitor mode select switch 2 system is abnormal Not set MON Display of the character display cannot be selected normally. (Machine monitor mode select switch 2 Contents of trouble system is abnormal.) Action of controller None in particular. Not set
Problem that Display of the character display cannot be selected normally. (Machine monitor mode select switch 2 appears on machine system is abnormal.) Related information Failure code is not displayed.
Action code
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CH2. 3) Check the switch.
Machine monitor mode se1 lect switch 2 system defective
Between CH2 (male) (2) (3)
Press [>] of the machine monitor select switch 2. Set the machine monitor select switch in NEUTRAL. Between Set the machine monitor select switch in NEUTRAL. CH2 (male) (1) Press [<] of the machine monitor (3) select switch 2.
Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CH2, and fuse BT2 terminal (2). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (2) CH2 Resistance Max. 1 z ness (female) (3) 2 (Disconnection or defective Wiring harness between DPC2A (female) (6) contact) Resistance Max. 1 z CH2 (female) (2) Wiring harness between DPC2A (female) (15) Resistance Max. 1 z CH2 (female) (1) Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A and CH2. 3) Connect T-adapter. Wiring harness between DPC2A (female) (6) CH2 (female) (2) Voltage between DPC2A (female) (6), CH2 (female) (2) chassis ground Voltage between DPC2A (female) (15), CH2 (female) (1) chassis ground Max. 1 V
Wiring harness between DPC2A (female) (15) CH2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2A (6) chassis ground Between DPC2A (15) chassis ground
Max. 1 V
Press [>] of the machine monitor select switch 2. Set the machine monitor select switch in NEUTRAL. Set the machine monitor select switch in NEUTRAL. Press [<] of the machine monitor select switch 2.
Voltage Voltage Voltage Voltage
20 30 V Max. 1 V Max. 1 V 20 30 V
20-932
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-6
HD465-7, HD605-7
20-933
(1)
TROUBLESHOOTING
MON-7
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY

Action code Not set
Contents of trouble
Trouble Power mode select function does not work normally
When the power mode select switch is operated, the power mode select function does not work normally.

Problem that When the power mode select switch is operated, the power mode select function does not work norappears on machine mally. Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector PWM. 3) Check the switch.
Power mode select switch defective
Between PWM (male) (1) Set the power mode select switch (3) in HIGH POWER MODE (Press its Resistance Max. 1 z lower part: Normal work).
Set the power mode select switch Resistance Min. 1 M z in ECONOMY MODE (Press its upper part).
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PWM, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) PWM Resistance Max. 1 z (female) (1) in normal state contact) Wiring harness between DPC2A (female) (13) Resistance Max. 1 z PWM (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 3 Machine monitor defective Between DPC2A (13) chassis ground Set the power mode select switch in ECONOMY MODE (Press its upper part). Set the power mode select switch in HIGH POWER MODE (Press its lower part: Normal work). Voltage 20 30 V
Voltage
Max. 1 V
20-934
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-8
MON-8 SEAT BELT WARNING LAMP DOES NOT OPERATE NORMALLY

a) Lamp lights up while seat belt is fastened
Action code Not set Failure code Controller code Not set Not set Trouble Seat belt warning lamp does not operate normally 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 Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SBS. 3) Check the switch. Between SBS (male) (1) (2) Seat belt "Fastened" Resistance Max. 1 z Seat belt "Unfastened" Resistance Min. 1 M z
1 Seat belt switch defective
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) SBS Resistance Max. 1 z (female) (1) in normal state contact) Wiring harness between DPC2B (female) (11) Resistance Max. 1 z SBS (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (11) Seat belt "Fastened" chassis ground Seat belt "Unfastened" Voltage Voltage 20 30 V Max. 1 V
HD465-7, HD605-7
20-935
(10)
TROUBLESHOOTING
MON-8
b) Lamp does not light up while seat belt is unfastened

Action code Not set Failure code Controller code Not set MON Trouble Seat belt warning lamp does not operate normally 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 Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SBS. 3) Check the switch. Between SBS (male) (1) (2) Seat belt "Fastened" Resistance Max. 1 z Seat belt "Unfastened" Resistance Min. 1 M z
1 Seat belt switch defective
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes and standard value 2 ness Voltage between (Disconnection or defective in normal state Wiring harness between DPC2B DPC2B (female) (11), contact) Max. 1 V (female) (11) SBS (female) (2) SBS (female) (2) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert T-adapter. 4) Turn the starting switch ON. Between DPC2B (11) Seat belt "Fastened" chassis ground Seat belt "Unfastened" Voltage Voltage 20 30 V Max. 1 V
20-936
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-9
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 Not set Failure code Controller code Not set Not set Turn signals and hazard lamp do not operate normally Trouble a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Contents of trouble When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash

Problem that When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash appears on machine
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly, Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. Between R17 (male) (1) (2) 1 Possible causes and standard value in normal state Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF. 2) Disconnect connector R17. tive 3) Check the relay. 4) Apply voltage between R17 (male) (1) (2). Between R17 (male) (5) (3) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z No Yes Relay (R17) is normal Relay (R17) is defective
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors R17, FLB, FLL, CM, and R16. 3) Connect T-adapter. ness (Disconnection or defective Between R17 (female) (3) FLB Resistance Max. 1 z contact) Wiring harness between FLL CM (female) (6) Resistance Max. 1 z and branching point of R16 (female) (1), (3)
HD465-7, HD605-7
20-937
(10)
TROUBLESHOOTING
MON-9
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up
Action code Not set
Contents of trouble
Turn signals and hazard lamp do not operate normally Trouble b) When turn signal lever and hazard lamp switch are operated, 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 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
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, and R16. 3) Connect T-adapter. 1 Hot short in wiring harness
Resistance between Wiring harness between FLL, CM FLL, CM (female) (6), (female) (6), R16 (female) (1) R16 (female) (1), (3) and (3) chassis ground 1) Turn the starting switch OFF. 2) Replace the flasher.
Max. 1 z
2 Flasher defective
If the flasher is replaced, the failure is not repaired.
Flasher is normal
If the flasher is replaced, the failure is repaired. Flasher is defective
20-938
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-9
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)
Action code Not set
Contents of trouble
Turn signals and hazard lamp do not operate normally c) When turn signal lever is operated, turn signal lamps on either Trouble or both sides do not flash (When hazard lamp switch is operated, 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 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) Related information
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the lever. Between CM (male) (6) (7) Set the turn signal leResistance Max. 1 z ver in LEFT. Set the turn signal leResistance Min. 1 M z ver in RIGHT. Set the turn signal leResistance Min. 1 M z ver in LEFT. Set the turn signal leResistance Max. 1 z ver in RIGHT.
1 Turn signal lever defective
Between CM (male) (6) (8)
1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. Between R17 (male) (1) (2) 2 Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF. 2) Disconnect connector R17. tive 3) Check the relay. 4) Apply voltage between R17 (male) (1) (2). Between R17 (male) (5) (3) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z No Yes Relay (R17) is normal Relay (R17) is defective
1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 terminal (4). Disconnection in wiring har3) Connect T-adapter. ness (Disconnection or defective Wiring harness between fuse BT1 (4), R17 contact) (female) (6), FLB Resistance Max. 1 z
Wiring harness between CM (female) (6), FLL, Resistance Max. 1 z branching point of R16 (female) (1), (3)
HD465-7, HD605-7
20-939
(10)
TROUBLESHOOTING
MON-9
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)
Action code Not set
Contents of trouble
Turn signals and hazard lamp do not operate normally d) When hazard lamp switch is turned ON, any turn signal lamp Trouble 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 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). Related information
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Turn the hazard lamp switch ON. Resistance Max. 1 z HAZ (male) (1) Turn the hazard lamp switch OFF. Resistance Min. 1 M z (3) 1) Turn the starting switch OFF. 2) Replace R16 with normal one. 3) Turn the starting switch ON. When hazard relay 1 (R16) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R16. 3) Check the relay. Between R16 (male) (5) (6) Resistance 200 400 z 1) Turn the starting switch OFF. 2) Disconnect connector R16. 3) Check the relay. 4) Apply voltage between R16 (male) (5) (6). Between R16 (male) (1) (2) Apply 24 V between (5) (6). Resistance Max. 1 z No Yes Relay (R16) is normal Relay (R16) is defective
Hazard lamp switch defective
Hazard relay 1 (R16) defecPossible causes 2 tive and standard value in normal state
1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is reHazard relay 2 (R17) defec- placed, is failure repaired? 3 tive 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. Between R17 (male) (1) (2) No Yes Relay (R17) is normal Relay (R17) is defective
20-940
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-9
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. 4) Apply voltage between R17 (male) (1) (2).
Hazard relay 2 (R17) defec- Between R17 (male) 3 (5) (3) tive
Apply 24 V between (1) (2).
Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 terminal (4). 3) Connect T-adapter. Wiring harness between fuse BT1 (24) R17 Resistance Max. 1 z (female) (5) Disconnection in wiring harWiring harness between R16 (female) (6) ness 4 (Disconnection or defective chassis ground contact) Wiring harness between R17 (female) (2) chassis ground Wiring harness between FLL and R16 (female) Resistance Max. 1 z (1) (3) Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between fuse BT2 (24) HAZ Resistance Max. 1 z (female) (1) Wiring harness between HAZ (female) (3) R16 (female) (5) Wiring harness between HAZ (female) (3) R17 (female) (1) Resistance Max. 1 z Resistance Max. 1 z
HD465-7, HD605-7
20-941
(10)
TROUBLESHOOTING
MON-9
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)
Action code Not set
Contents of trouble
Turn signals and hazard lamp do not operate normally e) When hazard lamp switch is turned OFF, turn signal lamps Trouble continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally)
When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal 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). Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Turn the hazard lamp switch ON. Resistance Max. 1 z HAZ (male) (1) Turn the hazard lamp switch OFF. Resistance Min. 1 M z (3) 1) Turn the starting switch OFF. 2) Replace R16 with normal one. 3) Turn the starting switch ON. When hazard relay 1 (R16) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R16. 3) Check the relay. Between R16 (male) (5) (6) Resistance 200 400 z No Yes Relay (R16) is normal Relay (R16) is defective
Hazard lamp switch defective
Hazard relay 1 (R16) defec- 1) Turn the starting switch OFF. 2 2) Disconnect connector R16. tive Possible causes 3) Check the relay. and standard value 4) Apply voltage between R16 (male) (5) (6). in normal state Apply 24 V between Resistance Max. 1 z Between R16 (male) (5) (6). (1) (2) Do not apply 24 V beResistance Min. 1 M z tween (5) (6). Between R16 (male) (3) (4) Apply 24 V between (5) (6). Resistance Min. 1 M z
1) Turn the starting switch OFF. 2) Disconnect connectors HAZ, R17, and R16. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between HAZ Wiring harness between HAZ (fe- (female) (3), R16 (female) (3) R16 (female) (5) male) (5) chassis ground Voltage between HAZ Wiring harness between HAZ (fe- (female) (3), R17 (female) (3) R17 (female) (1) male) (1) chassis ground
Max. 1 V
Max. 1 V
20-942
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-9
f)
Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however)
Action code Not set Failure code Controller code Not set MON Turn signals and hazard lamp do not operate normally Trouble f) Turn signal pilot lamps do not flash normally (Turn signal 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
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly, Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connectors BTC2A and R16. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between DPC2A (female) (7) Resistance Max. 1 z (Disconnection or defective R16 (female) (4) contact) Wiring harness between DPC2A (female) (16) Resistance Max. 1 z R16 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between Set the turn signal lever in RIGHT. DPC2A (7) chas- Set the turn signal lever in NEUsis ground TRAL. Between Set the turn signal lever in NEUTRAL. DPC2A (7) chassis ground Set the turn signal lever in LEFT. (*) Voltage changes alternately. Voltage Voltage Voltage Voltage Max. 1 V / 20 30 V (*) Max. 1 V Max. 1 V Max. 1 V / 20 30 V (*)
HD465-7, HD605-7
20-943
(10)
TROUBLESHOOTING
MON-9
20-944
(1)
HD465-7, HD605-7
TROUBLESHOOTING
MON-10
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 Not set
Contents of trouble
Night lighting is abnormal Trouble a) When lamp switch is set in 1st or 2nd position, any of small 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 lamp does not light up.

Problem that When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head appears on machine lamp does not light up.
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors CM fuse BT1 (2) 3) Insert T-adapter. ness 2 (Disconnection or defective 4) Turn the starting switch ON. contact) Wiring harness between BT1 (2) Voltage between CM CM (female) (1) (1) chassis ground
1 Lamp switch defective Possible causes and standard value in normal state
20 30 V
HD465-7, HD605-7
20-945
(10)
TROUBLESHOOTING
MON-10
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up
Action code Not set Failure code Controller code Not set Not set Night lighting is abnormal Trouble b) When lamp switch is set in 1st position, small lamp and night 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
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors CM and fuse BT1 (2) Disconnection in wiring har- 3) Insert T-adapter. ness 4) Turn the starting switch ON. 2 (Disconnection or defective Wiring harness between CM (fecontact) Voltage between CM male) (2), DPC2B (female), (2) chassis ground branching point of BT1 (1), (11)
20 30 V
20-946
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-10
c) When lamp switch is OFF, small lamp and night lamp light up
Action code Not set Failure code Controller code Not set MON Trouble Night lighting is abnormal 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 Related information Failure code is not displayed.
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, LS, fuse BT1 (2), and tachograph. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between CM (female) (2), DPC2B (female), branching point of BT1 (1), (11) Voltage between CM (female) (2) chassis ground Max. 1 V
HD465-7, HD605-7
20-947
(10)
TROUBLESHOOTING
MON-10
d) When dimmer switch is operated, brightness of night lighting does not change
Action code Not set Failure code Controller code Not set Not set Night lighting is abnormal Trouble d) When dimmer switch is operated, brightness of night lighting 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
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, fuse BT1 (9), (11), Switch, and Tachograph. 3) Insert T-adapter. 4) Turn the starting switch ON. Disconnection in wiring harWiring harness between LS (female) (3) ness chassis ground 1 (Disconnection or defective Wiring harness between LS (female) (2) contact) DPC2B (female) (12) (branching point of Switch) Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between LS (female) (1), DPC2B (female) (5) branching point of BT1 Resistance Max. 1 z (9), (11) Tachograph 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Set the lamp switch in 1st position. Between LS (1) (3) Between LS (2) (3) Voltage Voltage 20 30 V 6 27 V
2 Dimmer switch defective
20-948
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-10
e) Head lamp "Hi" beam does not light up

Action code Not set Failure code Controller code Not set Not set Trouble Night lighting is abnormal e) Head lamp "Hi" beam does not light up
Contents of trouble The head lamp cannot be set to "Hi" or "Lo".

Problem that The head lamp cannot be set to "Hi" or "Lo". appears on machine
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Replace R30 with normal one. 3) Turn the starting switch ON. When head lamp "Lo" relay (R30) is replaced, is failure repaired? 1) Turn the starting switch OFF. 2) Disconnect connector R30. 3) Check the relay. Between R30 (male) (1) (2) 1) Turn the starting switch OFF. 2) Disconnect connector R30. 3) Check the relay. 4) Apply voltage between R30 (male) (1) (2). Between R30 (male) (3) (5) Apply 24 V between (1) (2). Resistance Max. 1 z Resistance 200 400 z No Yes Relay R30 Relay R30
1 Lamp switch defective
Possible causes Head lamp "Hi" relay (R30) and standard value 2 defective in normal state
1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, fuse BT1 (9) (11), Switch, and Tachograph 3) Insert T-adapter. 4) Connect the connectors. Disconnection in wiring har5) Turn the starting switch ON. ness 3 (Disconnection or defective Wiring harness between R30 (female) (1), (3) Resistance Max. 1 z branching point of wiring harness contact) Wiring harness between R30 (female) (2) DCP1 (female) (14) Wiring harness between R30 (female) (5) branching point of wiring harness Resistance Max. 1 z Resistance Max. 1 z
HD465-7, HD605-7
20-949
(10)
TROUBLESHOOTING
MON-10
f)
Head lamp "Lo" beam does not light up

Action code Not set Failure code Controller code Not set Not set Trouble Night lighting is abnormal f) Head lamp "Lo" beam does not light up
Contents of trouble The head lamp "Lo" beam does not light up.

Problem that The head lamp "Lo" beam does not light up. appears on machine
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1 terminals (5) and (6) 3) Connect T-adapter. Wiring harness between PL1 (female) (1) chassis ground Resistance Max. 1 z
1 Lamp switch defective
Disconnection in wiring har- Wiring harness between PR1 (female) (1) Resistance Max. 1 z ness chassis ground 2 (Disconnection or defective Wiring harness between battery relay terminal contact) M (CN-02), fuse BT1 terminals (1), (2), CM Resistance Max. 1 z (female) (1) Wiring harness between CM (female) (3) fuse BT1 terminal (7) Wiring harness fuse BT1 terminal (8) PL1 (female) (1), PR1 (female) (1) Resistance Max. 1 z Resistance Max. 1 z
20-950
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-10
g) Head lamp cannot be set to "Hi" or "Lo"

Night lighting is abnormal Trouble g) Head lamp cannot be set to "Hi" or "Lo" Not set Not set Contents of trouble The head lamp "Hi" beam does not light up. Not set Action of controller None in particular.
Problem that The head lamp "Hi" beam does not light up. appears on machine
Action code
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Set the passing switch in RAISE Resistance Max. 1 z Between (PASS) position. CM (male) Set the passing switch in RETURN (4) (5) Resistance Min. 1 M z (OFF) position. 1) Turn the starting switch OFF. 2) Replace R29 with normal one. 3) Turn the starting switch ON. Relay R29 No When head lamp "Hi" relay (R29) is replaced, is failure repaired? Yes Relay R29 1) Turn the starting switch OFF. 2) Disconnect connector R29. 3) Check the relay. Between R29 (male) (1) (2)
1 Passing switch defective
Head lamp "Passing" relay (R29) defective
1) Turn the starting switch OFF. 2) Disconnect connector R29. 3) Check the relay. 4) Apply voltage between R29 (male) (1) (2). Apply 24 V between Resistance Max. 1 z Between R29 (male) (1) (2). (3) (5) Do not apply 24 V beResistance Min. 1 M z tween (1) (2). 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1 terminals (5) and (6) 3) Connect T-adapter. Wiring harness between PL2 (female) (1) chassis ground Wiring harness between PR2 (female) (1) chassis ground Disconnection in wiring harWiring harness between fuse BT1 terminal (6) ness 3 (Disconnection or defective PL2 (female) (1), PR2 (female) (1) contact) Wiring harness between R29 (female) (2) chassis ground Wiring harness between R29 (female) (3) branching point of wiring harness Wiring harness between CM (female) (5) R29 (female) (1) Wiring harness between CM (female) (4) branching point of wiring harness Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
HD465-7, HD605-7
20-951
(10)
TROUBLESHOOTING
MON-10
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up
Action code Not set Failure code Controller code Not set Not set Night lighting is abnormal Trouble h) When head lamp is set to "Hi" beam, pilot lamp of machine 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
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. Failure code is not displayed. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors DPC2A, CM, and R29. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between DPC2A (female) (4) contact) Resistance Max. 1 z CM (female) (5) R29 (female) (1) Possible causes and standard value in normal state 2 Machine monitor defective 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Set the passing switch Between DPC2A (5) in "Lo". chassis ground Set the passing switch in "Hi". Voltage Voltage Max. 1 V 20 30 V
20-952
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-10
HD465-7, HD605-7
20-953
(2)
TROUBLESHOOTING
MON-10
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY

a) Operating left side does not
Action code Not set Failure code Controller code Power window does not operate normally Trouble a) Operating left side does not Not set Not set
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 Related information
Before performing troubleshooting, check that fuses BT2 (8) are not broken. (If any of them is broken, there is a ground fault. Accordingly, check the related wiring harness.) Cause Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF. 2) Disconnect connector R34. 3) Check the switch. Power window switch (L.H.) "Left Between up" R34 Power window switch (L.H.) "OFF" Power window switch (L.H.) (male) (1) Power window switch (L.H.) "Left 1 (2) defective down" Power window switch (L.H.) "Left Between up" R34 Power window switch (L.H.) "OFF" (male) (1) Power window switch (L.H.) "Left (3) down" 1) Turn the starting switch OFF. 2) Replace R25 with normal one. Power window relay (R25) 3) Turn the starting switch ON. 2 defective No When power window relay (R25) is replaced, is failure repaired? Yes
Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z
Relay R25 is normal Relay R25 is defective
1) Turn the starting switch OFF. 2) Disconnect connectors R25, R34, PWL, and fuse BT2 terminal (8). Possible causes 3) Insert T-adapter. and standard value 4) Connect the connectors. in normal state 5) Turn the starting switch ON. Wiring harness between fuse BT2 terminal (8) Resistance Max. 1 z R34 (female) (1) Wiring harness between fuse BT2 terminal (8) Resistance Max. 1 z Disconnection in wiring har- R25 (female) (8) ness Wiring harness between R25 (female) (2) 3 Resistance Max. 1 z (Disconnection or defective R34 (female) (3) contact) Wiring harness between R25 (female) (1) Resistance Max. 1 z CAB1 (5) PWL (female) (1) Wiring harness between R25 (female) (5) CAB1 (6) PWL (male) (1) Resistance Max. 1 z
Wiring harness between R25 (female) (4) Resistance Max. 1 z R34 (female) (2) Wiring harness between R25 (female) (3) Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Replace power window motor (L.H.) with motor normal one. 3) Turn the starting switch ON. Power window motor (L.H.) aIf the results of 1 3 above are normal, perform the following test. 4 defective Motor is normal When power window motor (L.H.) No is motor replaced, is failure reYes Motor is defective placed ?
20-954
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-11
b) Operating right side does not

Power window does not operate normally Trouble b) Operating right side does not Not set Not set Contents of trouble The power window does not operate normally. (Operating right side does not) Not set Action of controller None in particular.
Problem that The power window does not operate normally. (Operating right side does not) appears on machine Related information
Action code
Before performing troubleshooting, check that fuses BT2 (10) are not broken. (If any of them is broken, there is a ground fault. Accordingly, check the related wiring harness.) Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R35. 3) Check the switch. Power window switch (R.H.) "Right Resistance Min. 1 M z Between up" R35 Power window switch (R.H.) "OFF" Resistance Min. 1 M z Power window switch (R.H.) (male) (1) 1 Power window switch (R.H.) "Right (2) Resistance Max. 1 z defective down" Power window switch (R.H.) "Right Resistance Max. 1 z Between up" R35 Power window switch (R.H.) "OFF" Resistance Min. 1 M z (male) (1) Power window switch (R.H.) "Right (3) Resistance Min. 1 M z down" 1) Turn the starting switch OFF. 2) Replace R25 with normal one. 3) Turn the starting switch ON. When power window relay (R25) is replaced, is failure repaired? No Yes Relay R25 is normal Relay R25 is defective Cause
Power window relay (R25) defective
1) Turn the starting switch OFF. 2) Disconnect connectors R25, R35, PWR, and fuse BT2 terminal (10). 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Wiring harness between fuse BT2 terminal (10) R35 (female) (1) Wiring harness between fuse BT2 terminal Disconnection in wiring har- (10) R25 (female) (11) ness Wiring harness between R25 (female) (7) 3 (Disconnection or defective R35 (female) (3) contact) Wiring harness between R25 (female) (6) CAB1 (7) PWR (female) (1) Wiring harness between R25 (female) (10) CAB1 (8) PWR (male) (1) Wiring harness between R25 (female) (9) R35 (female) (2) Wiring harness between R25 (female) (3) chassis ground Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Replace power window motor (R.H.) with motor normal one. 3) Turn the starting switch ON. Power window motor (R.H.) a If the results of 1 3 above are normal, perform the following test. 4 defective Motor is normal When power window motor (R.H.) No is motor replaced, is failure reMotor is defective Yes placed ?
HD465-7, HD605-7
20-955
(10)
TROUBLESHOOTING
MON-11
20-956
(2)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
MON-12 DEFECTIVE AIR CONDITIONER

a) Air conditioner does not operate
Action code Not set Failure code Controller code Defective air conditioner Trouble a) Air conditioner does not operate Not set Not set
Contents of trouble The air conditioner does not operate.

Problem that The air conditioner does not operate. appears on machine Related information
If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for ground fault. Cause Standard value in normal state/Remarks on troubleshooting
1) Turn starting switch OFF. 2) Disconnect connector ACP1 and fuse BT3 (4) terminal. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness 1 Wiring harness between fuse BT3 (4) ACP1 and standard value Resistance Max. 1 z (Disconnection or defective (female) (1) in normal state contact) Wiring harness between ACP1 (female) (14) Resistance Max. 1 z chassis ground 2 Defective air conditioner control panel a Check the control panel and repair or replace it, if it has abnormality.
HD465-7, HD605-7
20-957
(10)
TROUBLESHOOTING
MON-12
b) Air does not come out or air flow cannot be adjusted

Defective air conditioner Trouble b) Air does not come out or air flow cannot be adjusted Not set Not set Contents of trouble Air does not come out or air flow cannot be adjusted Not set Action of controller None in particular.
Problem that Air does not come out or air flow cannot be adjusted appears on machine Related information
Action code
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACR1, ACR2, ACR3, and ACR4 and fuse terminals BT1 (18) and BT3 (4). 3) Connect T-adapter. Wiring harness between fuse BT3 (4) ACR1 Resistance Max. 1 z (female) (1) Resistance Max. 2 z Resistance Max. 3 z Resistance Max. 4 z Resistance Max. 1 z
Disconnection in power Wiring harness between fuse BT3 (4) ACR2 supply wiring harness (Disconnection or defective (female) (1) contact) Wiring harness between fuse BT3 (4) ACR3 (female) (1) Wiring harness between fuse BT3 (4) ACR4 (female) (1) Wiring harness between fuse BT1 (18) ACR1 (female) (3)
1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5, ACBM, and ACRE. 3) Connect T-adapter. Wiring harness between ACP1 (female) (2) Resistance Max. 1 z ACR1 (female) (2) Wiring harness between ACP1 (female) (5) Resistance Max. 1 z ACR2 (female) (2) Wiring harness between ACP1 (female) (4) Resistance Max. 1 z ACR3 (female) (2) Wiring harness between ACP1 (female) (3) Resistance Max. 1 z ACR4 (female) (2) Disconnection in wiring harness 2 (Disconnection or defective contact) Wiring harness between ACR1 (female) (4) Resistance Max. 1 z ACBM (female) (1) Wiring harness between ACR2 (female) (3) ACBM (female) (2), ACRE (female) (1) Wiring harness between ACR3 (female) (3) ACRE (female) (2) Wiring harness between ACR4 (female) (3) ACRE (female) (3) wiring harness between ACR2 (female) (4) chassis ground wiring harness between ACR3 (female) (4) chassis ground wiring harness between ACR4 (female) (4) chassis ground wiring harness between ACRE (female) (4) chassis ground Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
20-958
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5, ACBM, and ACRE. 3) Connect T-adapter. Wiring harness between Resistance between ACR1 ACR1 (female) (4) ACBM (female) (4), ACBM (female) Min. 1 M z (female) (1) (1) chassis ground
Wiring harness between ACR2 (female) (3) ACBM (female) (2), ACRE (female) (1)
Resistance between ACR2 (female) (3), ACBM (female) Min. 1 M z (2), ACRE (female) (1) chassis ground
Wiring harness between Resistance between ACR3 ACR3 (female) (3) ACRE (female) (3), ACRE (female) Min. 1 M z (female) (2) (2) chassis ground Wiring harness between Resistance between ACR4 ACR4 (female) (3) ACRE (female) (3), ACRE (female) Min. 1 M z (female) (3) (3) chassis ground 1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4 Defective blower main relay 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Replace motor. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Replace motor Condition becomes normal. with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Disconnect connector ACRE. 3) Check resistor unit. 9 Defective blower resistor Between ACRE (female) (1) (2) Between ACRE (female) (1) (3) Between ACRE (female) (1) (4) 10 Defective air conditioner control panel Resistance Resistance Resistance 2.8 z 4.8 z 4.0 z
5 Defective blower Hi relay Possible causes and standard value in normal state
6 Defective blower M2 relay
7 Defective blower M1 relay
8 Defective blower motor
a Check the control panel and repair or replace it, if it has abnormality.
HD465-7, HD605-7
20-959
(10)
TROUBLESHOOTING
MON-12
c) Air is not cooled or temperature cannot be adjusted (Electric system)

Defective air conditioner Trouble c) Air is not cooled or temperature cannot be adjusted (Electric Not set Not set Not set system) Contents of trouble Air is not cooled or temperature cannot be adjusted Action code Failure code Controller code Action of controller None in particular.
Problem that Air is not cooled or temperature cannot be adjusted appears on machine Related information
If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for ground fault. If fuse BT1 (18) is broken, check the wiring harness between fuse BT1 (18) and ACR5 (female) (3) for grounding fault. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACR5 and fuse terminals BT1 (18) and BT3 (4). 3) Connect T-adapter.
Disconnection in power supply wiring harness 1 Wiring harness between fuse BT3 (4) ACR5 Resistance Max. 5 z (Disconnection or defective (female) (1) contact) Wiring harness between fuse BT1 (18) ACR5 Resistance Max. 1 z (female) (3) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH, ACPS, and E07. 3) Connect T-adapter. Wiring harness between ACP1 (female) (6) Resistance Max. 1 z ACPS (female) (2) Wiring harness between ACP1 (female) (9) Resistance Max. 1 z ACTH (female) (1) Wiring harness between ACP1 (female) (10) Resistance Max. 1 z ACM1(female) (4) Wiring harness between ACP1 (female) (13) Disconnection in wiring har- ACTH (female) (2) 2 ness (Disconnection or deWiring harness between ACP1 (female) (13) fective contact) ACM1 (female) (3) Possible causes and standard value Wiring harness between ACP1 (female) (16) in normal state ACM1 (female) (1) Wiring harness between ACP2 (female) (3) ACM1 (female) (2) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
Wiring harness between ACP2 (female) (4) Resistance Max. 1 z ACM1 (female) (5) Wiring harness between ACR5 (female) (2) Resistance Max. 1 z ACPS (female) (1) Wiring harness between ACR5 (female) (4) Resistance Max. 1 z E07 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH, ACPS, and E07. 3) Connect T-adapter. Wiring harness between ACP1 (female) (6) ACPS (female) (2) Wiring harness between ACP1 (female) (9) ACTH (female) (1) Resistance between ACP1 (female) (6), ACPS (female) Min. 1 M z (2) chassis ground Resistance between ACP1 (female) (9), ACTH (female) Min. 1 M z (1) chassis ground
Resistance between ACP1 Wiring harness between ACP1 (female) (10) ACM1 (female) (10), ACM1 (female) Min. 1 M z (female) (4) (4) chassis ground
20-960
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
Cause
Standard value in normal state/Remarks on troubleshooting Wiring harness between Resistance between ACP1 ACP1 (female) (13) ACTH (female) (13), ACTH (female) Min. 1 M z (female) (2) (2) chassis ground Wiring harness between Resistance between ACP1 ACP1 (female) (13) ACM1 (female) (13), ACM1(female) Min. 1 M z (female) (3) (3) chassis ground Wiring harness between Resistance between ACP1 ACP1 (female) (16) ACM1 (female) (16), ACM1 (female) Min. 1 M z (female) (1) (1) chassis ground Wiring harness between ACP2 (female) (3) ACM1 (female) (2) Wiring harness between ACP2 (female) (4) ACM1 (female) (5) Wiring harness between ACP2 (female) (7) ACM2 (female) (1) Wiring harness between ACR5 (female) (2) ACPS (female) (1) Resistance between ACP2 (female) (3), ACM1 (female) (2) chassis ground Resistance between ACP2 (female) (4), ACM1 (female) (5) chassis ground Resistance between ACP2 (female) (7), ACM2 (female) (1) chassis ground Resistance between ACR5 (female) (2), ACPS (female) (1) chassis ground Min. 1 M z Min. 1 M z Min. 1 M z Min. 1 M z Min. 1 M z
Wiring harness between Resistance between ACR5 ACR5 (female) (4) E07 (fe- (female) (4), E07 (female) male) (1) (1) chassis ground
1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. Defective compressor clutch 4) Start air conditioner. 4 relay Possible causes Relay is defective. Condition becomes normal. and standard value Replace relay in normal state with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Disconnect connector ACPS. 3) Connect T-adapter. 4) Turn starting switch ON. Air conditioner switch OFF Between ACPS (male) (1) (2) Air conditioner switch ON in cooling mode 1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch ON. 4) Start air conditioner. Between ACTH (male) Temperature: 25C (1) (2) Temperature: 100C 1) Turn starting switch OFF. 2) Replace motor. 3) Turn starting switch ON. 4) Start air conditioner. Motor is defective. Replace motor Condition becomes normal. with normal one. Condition does not become normal. Motor is normal. 1) Turn starting switch OFF. 2) Replace air conditioner compressor. 3) Turn starting switch ON. 4) Start air conditioner. Replace air Condition becomes normal. Compressor is defective. conditioner compressor with Condition does not become Compressor is normal. normal. normal one. Resistance 37 50 k z Resistance 3.5 4.0 k z Resistance Min. 1 M z Resistance Max. 1 z
5 Defective pressure switch
6 Defective thermistor
Defective temperature adjustment servomotor
Defective air conditioner compressor
HD465-7, HD605-7
20-961
(10)
TROUBLESHOOTING
MON-12
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace diode (E08). Replace diode (E08) with normal one. Condition becomes normal. Diode (E08) is defective. Condition does not become normal. Diode (E08) is normal.
Possible causes 9 Defective diode (E08) and standard value in normal state 10 Defective air conditioner control panel
d) Recirculated air and fresh air cannot be selected

Defective air conditioner Trouble d) Recirculated air and fresh air cannot be selected Not set Not set Contents of trouble Recirculated air and fresh air cannot be selected because of a defect in the air conditioner system. Not set Action of controller None in particular.
Problem that Recirculated air and fresh air cannot be selected. appears on machine Related information
Action code
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP2 and ACM3. Disconnection in wiring 3) Connect T-adapter. harness 1 Wiring harness between ACP2 (female) (5) (Disconnection or defective Resistance Max. 1 z ACM3 (female) (2) contact) Wiring harness between ACP2 (female) (6) Resistance Max. 1 z ACM3 (female) (5) Possible causes and standard value in normal state 2 Ground fault in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors ACP2 and ACM3. 3) Connect T-adapter. Wiring harness between Resistance between ACP2 ACP2 (female) (5) ACM3 (female) (5), ACM3 (female) Min. 1 M z (female) (2) (2) chassis ground Wiring harness between Resistance between ACP2 ACP2 (female) (6) ACM3 (female) (6), ACM3 (female) Min. 1 M z (female) (5) (5) chassis ground a Check the control panel and repair or replace it, if it has abnormality.
Cause
Defective air conditioner control panel
20-962
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
e) Air outlets cannot be selected

Defective air conditioner Trouble e) Air outlets cannot be selected Not set Not set Contents of trouble Air outlets cannot be selected Not set Action of controller None in particular.
Problem that Air outlets cannot be selected appears on machine Related information
Action code
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, and ACM2. 3) Connect T-adapter. Wiring harness between ACP1 (female) (11) Resistance Max. 1 z ACM2 (female) (4) Disconnection in wiring Wiring harness between ACP1 (female) (13) Resistance Max. 1 z harness ACM2 (female) (3) 1 (Disconnection or defective Wiring harness between ACP2 (female) (1) contact) Resistance Max. 1 z ACM2 (female) (2) Wiring harness between ACP2 (female) (2) Resistance Max. 1 z ACM2 (female) (5) Wiring harness between ACP2 (female) (7) Resistance Max. 1 z ACM2 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, and ACM2. 3) Connect T-adapter. Resistance between ACP1 Wiring harness between ACP1 (female) (11) ACM2 (female) (11), ACM2 (female) Min. 1 M z (female) (4) (4) chassis ground Resistance between ACP1 Wiring harness between ACP1 (female) (13) ACM2 (female) (13), ACM2 (female) (female) (3) (3) chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (1) ACM2 (female) (1), ACM2 (female) (female) (2) (2) chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (2) ACM2 (female) (2), ACM2 (female) (female) (5) (5) chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (7) ACM2 (female) (7), ACM2 (female) (female) (1) (1) chassis ground Min. 1 M z
Cause
Ground fault in wiring har2 ness
Min. 1 M z
Min. 1 M z
Min. 1 M z
Defective air conditioner control panel
HD465-7, HD605-7
20-963
(10)
TROUBLESHOOTING
MON-12
20-964
(5)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
f)
Air is not cooled (Mechanical system)

Defective air conditioner Trouble f) Air is not cooled (Mechanical system) Not set Not set Contents of trouble Air is not cooled because of abnormality in mechanical system. Action of controller None in particular.
Problem that Air is not cooled because of abnormality in mechanical system. appears on machine Related information
Cause Gas leakage through pipe 1 joints or parts 2 Natural leakage through hose, etc. (Refrigerant has not been added for long time)
Standard value in normal state/Remarks on troubleshooting Check and repair or replace, if abnormal. Check refrigerant level and add new refrigerant to proper level, if nec essary. Add new refrigerant to proper level. Check and repair or replace, if abnormal. a Check the valve for excessive opening and defective contact of heat-sensor tube, too. Check and remove clogging material, if there is any, or replace. Check and remove clogging material, if there is any, and clean evaporator. Check and clean, or replace. Check and repair or replace, if abnormal. Check and repair or replace leaking part. Increase set air flow. Check refrigerant level and reduce it to proper level, if necessary. Evacuate system and fill it with refrigerant to proper level and replace receiver drier. Check fins for clogging and clean them, if necessary. Check and repair or replace, if necessary. Evacuate system and fill it with refrigerant to proper level and replace receiver drier.
3 Insufficient refrigerant level 4 Defective expansion valve 5 Clogging of low-pressure circuit and evaporator
6 Clogging of evaporator fins Possible causes and standard value 7 Clogging of filter in normal state Defective installation of ther8 mistor Air leakage through air con9 ditioner unit and duct 10 Insufficient set air flow 11 Excessive refrigerant 12 Entry of air 13 Clogging of condenser fins Insufficient compression by 14 compressor Entry of water in refrigerant 15 circuit
HD465-7, HD605-7
20-965
(10)
TROUBLESHOOTING
MON-12
g) Air is not heated (Defective hot water circuit)

Defective air conditioner Trouble g) Air is not heated (Defective hot water circuit) Not set Not set Contents of trouble Air is not heated (Defective hot water circuit). Not set Action of controller None in particular.
Problem that Air is not heated (Defective hot water circuit). appears on machine Related information
Action code
Check that water is not leaking through the hot water circuit. Check that air is flowing out of the air outlets. Standard value in normal state/Remarks on troubleshooting Check heater core fins for clogging and clean them, if necessary. 1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet of the heater core becomes high. Check and repair or replace leaking part. Air leakage through air con2 a If this is the cause, the temperature at the hot water inlet and outlet ditioner unit of the heater core becomes high. Cause
Possible causes Check and remove clogging material, or replace valve. and standard value 3 Defective water valve a If this is the cause, the temperature at the hot water inlet of the heat(Clogging or defective valve) in normal state er core becomes high but that at the hot water outlet becomes low. 4 Clogging of heater core Check and repair or replace leaking part. a If this is the cause, the temperature at the hot water inlet of the heater core becomes high but that at the hot water outlet becomes low. Check and repair or replace leaking part. a If this is the cause, the temperature at the hot water inlet of the heater core becomes low.
Clogging up to hot water inlet of heater core
h) Abnormal sound comes out

Defective air conditioner Trouble h) Abnormal sound comes out Not set Not set Contents of trouble Abnormal sound comes out. Not set Action of controller None in particular.
Problem that Abnormal sound comes out. appears on machine Related information
Action code
Cause Standard value in normal state/Remarks on troubleshooting Defective installation of bolts 1 Check and repair, if abnormal. (screws) related to case 2 Interference of fan case, etc. Check and repair or replace, if abnormal. or breakage of fan Check and remove foreign matter, if there is any, and repair or replace Check and replace, if abnormal sound (peep or gas leakage sound) comes out. Check and repair or replace, if loosened or worn. Check refrigerant level and reduce or increase it to proper level, if necessary. Check and repair or replace, if abnormal.
Entry of foreign matter in 3 blower motor or defective Possible causes blower motor and standard value in normal state 4 Defective expansion valve 5 6 Loosened or worn compressor V-belt
Insufficient or excessive refrigerant 7 Defective compressor
20-966
(10)
HD465-7, HD605-7
TROUBLESHOOTING
MON-12
i)
Water leaks
Action code Not set Failure code Controller code Not set Trouble Defective air conditioner i) Water leaks
Not set Contents of trouble Water leaks.

Problem that Water leaks. appears on machine Related information
Cause Standard value in normal state/Remarks on troubleshooting Clogging of water drain hole Check and repair, if abnormal. 1 in air conditioner unit 2 Clogging, bend, defective installation, or breakage of Check and repair or replace, if abnormal. drain hose of air conditioner unit
Possible causes Breakage (Cracking) of air Check and repair or replace, if broken (cracked). and standard value 3 conditioner unit case in normal state Defective installation of bolts 4 (screws) related to air Check and repair or replace, if abnormal. conditioner unit case Defective joints of hot water Check and repair or replace, if abnormal. circuit piping 6 Defective heater core Check and repair or replace, if abnormal. 5 7 Defective water valve Check and repair or replace, if abnormal.
HD465-7, HD605-7
20-967
(10)
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)

Electricahot short in wiring harnessl system diagram related VHMS controller ........................................ 20-1002 Information given in troubleshooting chart ................................................................................................ 20-1004 Phenomenon type code list....................................................................................................................... 20-1005 [A000N1] (or VHMS_LED displays [n201]) Engine overrun ............................................................. 20-1006 [DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage.................................. 20-1006-1 [DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.... 20-1006-3 [DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24V) system... 20-1006-5 [DBB7KP] (or VHMS_LED indicates "n903") Abnormality in sensor power source (12V) system... 20-1006-7 [DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications: Defective communications (KR) (between engine controller and VHMS controller)............................................................ 20-1007 [DBBSKR] (or VHMS_LED displays [n803]) Defective S-NET communications: (KR) ...................... 20-1009 [DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground in engine oil temperature sensor system (KB) {30 min (at 500 rpm or above) after starting engine}..................................................................................................................20-1011 [DGE1KY] (or VHMS_LED displays [n241]) Short circuit with power source (Hot short) in engine oil temperature sensor system (KY).................................................................. 20-1012 [DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system: Input signal outside range (KX) ........................................................................................ 20-1013 [DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ........................................ 20-1014 [DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source in (Hot short) No. 1, 2, 3 (front) exhaust temperature sensor system (KB) ............................................ 20-1016 [DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA) ......................................... 20-1018 [DGT5KB] (or VHMS LED displays [n321]) Short circuit with power source (Hot short) in No. 4, 5, 6 (rear) exhaust temperature sensor system (KB) ......................................... 20-1020 [DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground in engine blow-by pressure sensor system (KA) .............................................................. 20-1022 [DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (Hot short) in engine blow-by pressure sensor system (KY) .............................................................. 20-1023 [DhP4KX] Suspension pressure sensor (Front right): Out of input signal range (KX).................... 20-1023-1 [DhP5KX] Suspension pressure sensor (Front left): Out of input signal range (KX) ...................... 20-1023-3 [DhP6KX] Suspension pressure sensor (Rear right): Out of input signal range (KX) .................... 20-1023-5 [DhP7KX] Suspension pressure sensor (Rear left): Out of input signal range (KX)....................... 20-1023-7 [DKH1KX] Pitch angle sensor: Out of input signal range (KX)........................................................ 10-1023-9 [F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .......................... 20-1024 [F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)............................................................................................................................. 20-1025 [F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)............................................................................................................................. 20-1026 [F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)............................................................................................................................. 20-1027 [F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)............................................................................................................................. 20-1028 VHMS-1 VHMS-1 Abnormality in satellite data communication a) Satellite communication data are not transmitted ......................................................... 20-1029 b) Abnormality in downloading into PC or setting of PC ................................................... 20-1032 VHMS-2 Abnormality in saving data in VHMS controller ................................................................. 20-1034 VHMS-3 Engine blow-by pressure indicated by monitor is low........................................................ 20-1036
HD465-7, HD605-7
20-1001
(10)
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
20-1002
(5)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-1003
(5)
TROUBLESHOOTING
20-1003-1
(5)
HD465-7, HD605-7
TROUBLESHOOTING
INFORMATION GIVEN IN TROUBLESHOOTING CHART
INFORMATION GIVEN IN TROUBLESHOOTING CHART

a The following type of information is given in the troubleshooting charts and related circuit diagrams, so make sure that you understand the content fully before starting troubleshooting.
Action code Shown on panel display Failure code Controller code Trouble Problem that appeared on machine Shown on Shown on panel display panel display
Contents of trouble Condition when monitor panel or controller detected failure.
Action of controller Action taken to protect system or equipment when monitor panel or controller detected failure.
Problem that Problem that appeared on machine when monitor panel or controller took above action. appears on machine Related information Information related to troubleshooting or failure that occurred.
Cause
Standard value in normal state/Remarks on troubleshooting <Content of information> Standard value when condition is normal (used to judge status of probable failure). Remarks used to judge status of probable failure. <Problems with wiring harness> Disconnection Defective connection of connector or disconnection in wiring harness. Ground fault Wiring harness not connected to GND (ground) circuit is in contact with GND circuit. Short circuit with power source (Hot short) Wiring harness not connected to power source (24V) circuit is in contact with power source circuit. Short circuit Wiring harnesses of independent circuits are in abnormal contact.
Probable cause Probable cause of existing and standard value 3 failure (the numbers are when normal index numbers and do not indicate the order of priority) <Precautions when troubleshooting> 1) Method of displaying connector No. and method of handling Tadapter If there are no special instructions, insert or connect the T-adapter as follows. 4 If there is no indication of (male) or (female) with the connector No., disconnect the connector and insert the T-adapter into both the male and female sides. If (male) or (female) is indicated with the connector No., disconnect the connector and insert the T-adapter into only the side indicated (either male or female). 2) Order of listing pin No. and method of handling test lead 5 If there are no special instructions, connect the (+) lead and () lead of the tester as follows. Connect the (+) lead to the pin No. or wiring harness given first. Connect the () lead to the pin No. or wiring harness given last.
20-1004
(10)
HD465-7, HD605-7
TROUBLESHOOTING
PHENOMENON TYPE CODE LIST
This is the section of the circuit diagram that shows the parts related to the failure. Connector No.: (type No. of pins) (color). Arrows ( ): Shows approximate mounting position on machine.
PHENOMENON TYPE CODE LIST

a For phenomenon type codes marked "See list", refer to this list.
Phenomenon code KA KB KK KQ KR KT KX KY KZ MA MB MW NS ZG ZK Contents Disconnection Short circuit Drop in power source voltage, input Mismatch in model selection signal Defective communications Abnormality inside controller Input signal outside range Short circuit with power source (Hot short) Disconnection or short circuit Defective function Drop in function Slippage Overheat Drop in oil pressure Drop in level Phenomenon code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents Fill signal for non-existent combination of clutches ON simultaneously for 2 or more channels. Fill signal ON when command current to ECMV is OFF. Fuel pressure is higher than max. specified value. Target components cannot be controlled. ON/OFF signals from 2 systems do not match. Engine speed signal, C terminal signal, oil pressure switch, coolant temperature sensor signals do not match operating condition or stopped condition. Analog signals of 2 systems do not match. Speed signals of 2 systems do not match. Switch remains pressed for length of time unthinkable for normal operations . Fill signal is turned OFF when command current to ECMV is ON.
HD465-7, HD605-7
20-1005
(10)
TROUBLESHOOTING
[A000N1]
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN

Action code Not set Failure code Controller code A000N1 Not set Trouble Engine overrun
Contents of trouble Engine speed of more than 2,625 rpm is detected when engine is running.
Action of controller Carries out control for default mode.

Problem that If machine continues to be used as it is, engine may be damaged. appears on machine
Engine speed can be checked with monitoring function (code: 01001) LED display is [n201] Related information If failure codes [C115KZ] or [C121LC] related to engine controller are displayed, carry out troubleshooting first for the applicable code. Cause 1 Engine overrun Defective engine speed Probable cause 2 sensor and standard value when normal 3 Defective VHMS controller Standard value in normal state/Remarks on troubleshooting Inspect engine and repair if any abnormality is found. Carry out troubleshooting for failure code [C115KZ] or [C121LC]. 1) Start engine. 2) Check with monitoring function (code: 01001). Monitoring code: High idle speed 01001 Power mode 2,270 50 rpm
20-1006
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DBB0KK]
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE VOLTAGE

Action code Not set Failure code Controller code DBB0KK Not set Trouble Abnormality source voltage
Contents of trouble The switch source voltage is below 9.5( 2.5)V or above 42.4( 6)V.

Problem that The system may not operate normally. appears on machine Related information VHMS controller LED indicates "n901".
Cause 1 Defective circuit breaker
Standard value in normal state/Remarks on troubleshooting If the circuit breaker is turned OFF, the circuit probably has grounding fault (See cause 3). 1) Turn starting switch OFF. 2) Disconnect connector HM-CN1 and battery relay terminal CN-02 (Terminal M). 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between HM-CN1 (female) (8), Resistance Max. 1 z 2 ness (Disconnection or de- (9) battery relay CN-02 (Terminal M) fective contact) Wiring harness between HM-CN1 (female) Resistance Max. 1 z (11), (12) ER Probable cause and standard value when normal Wiring harness between HM-CN1 (female) (19), (20) ER Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connector HM-CN1, battery relay terminal CN-02 (Terminal M), and connectors related to them. 3) Connect T-adapter. Wiring harness between Resistance between HMHM-CN1 (female) (8), (9) CN1 (female) (8), (9) chasbattery relay CN-02 (Termi- sis ground Min. 1 M z nal M) and wiring harnesses related to it 1) Turn starting switch OFF. 2) Disconnect HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (8), (9) chassis ground Voltage 20 30 V
4 Defective VHMS controller
HD465-7, HD605-7
20-1006-1
(10)
TROUBLESHOOTING
[DBB0KK]
20-1006-2
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DBB5KP]
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER SOURCE (5 V) SYSTEM
Action code Not set Failure code Controller code DBB5KP Not set Trouble Abnormality in sensor power source (5 V) system
Contents of trouble Sensor power source (5 V) voltage is out of the normal range (4.5 5.5 V).

Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-12. 3) Connect T-adapter. Wiring harness between HM-CN1 (female) (4), (5) HM-12 (female) (B) Resistance between HMCN1 (female) (4), (5), HMMin. 1 M z CN12 (female) (B) chassis ground
Probable cause and standard value when normal
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-12. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN1 (female) (4), (5) HM-12 (female) (B) Voltage between HM-CN1 (female) (4), (5), HM-12 (female) (B) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (4), (5) (11), (12) Voltage 4.5 5.5 V
HD465-7, HD605-7
20-1006-3
(10)
TROUBLESHOOTING
[DBB5KP]
20-1006-4
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DBB6KP]
Contents of trouble Sensor power source (24 V) voltage is out of the normal range (20 - 30V).

Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-23A, HM-23B, SUFR, SUFL, SURR, and SURL. 3) Connect T-adapter. Wiring harness between HM-CN1 (female) (2) HM23A (female) (A), HM-23B (female) (A) Wiring harness between HM-CN1 (female) (2) HMSUFL (female) (B), HMSUFR (female) (B) Wiring harness between HMCN1 (female) (2) HMSURL (female) (B), HMSURR (female) (B) Resistance between HMCN1 (female) (2), HM-23A (female) (A), HM-23B (female) chassis ground Min. 1 M z
Resistance between HMCN1 (female) (2), HM-SUFL Min. 1 M z (female) (B), HM-SUFR (female) (B) chassis ground Resistance between HMCN1 (female) (2), HM-SURL Min. 1 M z (female) (B), HM-SURR (female) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, GR-2, HM-23A, HM-23B, SUFR, SUFL, SURR, and SURL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN1 (female) (2) HM23A (female) (A), HM-23B (female) (A) Wiring harness between HM-CN1 (female) (2) HMSUFL (female) (B), HMSUFR (female) (B) Wiring harness between HM-CN1 (female) (2) HMSURL (female) (B), HMSURR (female) (B) Voltage between HM-CN1 (female) (2), HM-23A (female) (A), HM-23B (female) (A) chassis ground Voltage between HM-CN1 (female) (2), HM-SUFL (female) (B), HM-SUFR (female) (B) chassis ground Voltage between HM-CN1 (female) (2), HM-SURL (female) (B), HM-SURR (female) (B) chassis ground
Max. 1 V
Max. 1 V
Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (2) (11), (12) Voltage 20 30 V
HD465-7, HD605-7
20-1006-5
(10)
TROUBLESHOOTING
[DBB6KP]
20-1006-6
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DBB7KP]
Contents of trouble Sensor power source (12 V) voltage is out of the normal range (10 15 V).

Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and GDL. 3) Connect T-adapter. Wiring harness between Resistance between HMHM-CN1 (female) (3) GDL CN1 (female) (3), GDL Min. 1 M z (male) (1) (male) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and GDL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between Voltage between HM-CN1 HM-CN1 (female) (3) GDL (female) (3), GDL (male) (1) (male) (1) and chassis ground 1) Turn starting switch OFF. 2) Disconnect HM-CN1. 3) Insert T-adapter. 4) Turn starting switch ON. Between HM-CN1 (3) (11), (12) Voltage 10 15V Max. 1 V
Probable cause and standard value when normal 2 Hot short in wiring harness
HD465-7, HD605-7
20-1006-7
(10)
TROUBLESHOOTING
[DBB7KP]
20-1006-8
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DBBRKR]
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)
Action code E03 Failure code Controller code DBBRKR Not set Trouble Defective CAN communications: Defective communications (KR) (between engine controller and VHMS controller)
Contents of trouble Communications (CAN) data from engine controller cannot be obtained.
Action of controller Maintains condition existing when abnormality occurred.

Problem that VHMS function for obtaining data from engine controller not working. appears on machine
LED display is [n801]

Related information If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first
for the applicable code. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN4A and CAN1. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (4) CAN1 (female) (A) Wiring harness between HM-CN4A (female) (12) CAN1 (female) (B) Resistance Max. 1 z Resistance Max. 1 z
Disconnection in wiring harness 1 (disconnection, defective contact)
1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN4A and CAN1. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (4) CAN1 (female) (A) Wiring harness between HM-CN4A (female) (12) CAN1 (female) (B) Resistance between HMCN4A (female) (4), CAN1 (female) (A) chassis ground Resistance between HMCN4A (female) (12), CAN1 (female) (B) chassis ground Max. 1 z
Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN4A. 3) Connect T-adapter. 4) Turn starting switch ON. 3 Hot short in wiring harness Wiring harness between HM-CN4A (female) (4) CAN1 (female) (A) Wiring harness between HM-CN4A (female) (12) CAN1 (female) (B) Voltage between HM-CN4A (female) (4), CAN1 (female) (A) chassis ground Voltage between HM-CN4A (female) (12), CAN1 (female) (B) chassis ground Max. 1 V
Max. 1 V
1) Turn the starting switch OFF. 2) Replace VHMS controller. 3) Turn starting switch ON. 4 Defective VHMS controller Does not communicate Is communication normally normal when VHMS controller is replaced? Communicates normally VHMS controller normal VHMS controller defective
HD465-7, HD605-7
20-1007
(10)
TROUBLESHOOTING
[DBBRKR]
20-1008
(2)
HD465-7, HD605-7
TROUBLESHOOTING
[DBBSKR]
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR)

Action code E03 Failure code Controller code DBBSKR Not set Trouble Defective S-NET communications: (KR)
Contents of trouble Communications data from controller cannot be obtained.
Action of controller Machine monitor shows abnormal display screen (red) to warn operator of abnormality.
Problem that In some cases, system does not work normally. appears on machine Related information
If failure code [DAQSKR], [DBISKR] related to S-NET of other controllers is displayed, carry out troubleshooting first for the applicable code. LED display is [n803] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN3A, JCB, JCC, and JCD. 3) Connect T-adapter. Disconnection in wiring harness 1 (disconnection, defective contact) Wiring harness between HM-CN3A (female) (8) JCB (female) (8) Wiring harness between HM-CN3A (female) (18) JCD (female) (4) Wiring harness between HM-CN3A (female) (9) ,(17) JCC (female) (4), JCE (female) (4) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN3A, JCB, and JCD. 3) Connect T-adapter. Ground fault in wiring har2 ness Probable cause and standard value when normal Wiring harness between HM-CN3A (female) (8) JCB (female) (8) Wiring harness between HM-CN3A (female) (18) JCD (female) (4) Resistance between HMCN3A (female) (8), JCB (fe- Min. 1 Mz male) (8) chassis ground Resistance between HMCN3A (female) (18), JCD (female) (4) chassis ground Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN3A, JCB, and JCD. 3) Connect T-adapter. 3 Hot short in wiring harness Wiring harness between HM-CN3A (female) (8) JCB (female) (8) Wiring harness between HM-CN3A (female) (18) JCD (female) (4) Voltage between HM-CN3A (female) (18), JCB (female) (8) chassis ground Voltage between HM-CN3A (female) (18), JCD (female) (4) chassis ground Max. 1 V
Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN3A. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN3A (8) (17) Between HM-CN3A (18) (17) Voltage Voltage Max. 6 9 V Max. 6 9 V
HD465-7, HD605-7
20-1009
(10)
TROUBLESHOOTING
[DBBSKR]
20-1010
(2)
HD465-7, HD605-7
TROUBLESHOOTING
[DGE1KB]
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERUTURE SENSOR SYSTEM (KB) {30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}
Action code Not set Failure code Controller code DGE1KB Not set Disconnection, short circuit with chassis ground in engine oil Trouble temperature sensor system (KB) {30 min (at 500 rpm or above) after starting engine}
Contents of trouble Signal voltage of engine oil temperature sensor has dropped below 0.3V.

Problem that Engine oil temperature cannot be monitored with monitoring function. appears on machine Related information
Engine oil temperature can be checked with monitoring function (code: 42700). LED display is [n242] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HM-31. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-31 (male) (1) (2) 25 C 100 C Resistance Approx. 35 50 kz Resistance Approx. 3.3 4.3 kz
Defective engine oil temperature sensor
1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) HM-31 (female) (1) Wiring harness between HM-CN2A (female) (12) HM-31 (female) (2) Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) HM-31 (female) (1) Resistance between HMCN2A (female) (3), HM-31 (female) (1) chassis ground Min. 1 Mz
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. Between HM-CN2A (female) (3) (12) 25 C 100 C Resistance Approx. 35 50 kz Resistance Approx. 3.3 4.3 kz
HD465-7, HD605-7
20-1011
(10)
TROUBLESHOOTING
[DGE1KY]
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)
Action code Not set Failure code Controller code DGE1KY Not set Trouble Short circuit with power source (Hot short) in engine oil temperature sensor system (KY)
Contents of trouble Signal voltage of engine oil temperature sensor has risen above 4.9V.

Problem that Engine oil temperature cannot be monitored with monitoring function. appears on machine Related information
Engine oil temperature can be checked with monitoring function (code: 42700). LED display is [n241] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-31. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-31 (male) (1) (2) 25 C 100 C Resistance Approx. 35 50 kz Resistance Approx. 3.3 4.3 kz
Defective engine oil temperature sensor
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) HM-31 (female) (1) Voltage between HM-CN2A (female) (3), HM-31 (female) (1) chassis ground Max. 1 V
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. Between HM-CN2A (female) (3) (12) 25 C 100 C Resistance Approx. 35 50 kz Resistance Approx. 3.3 4.3 kz
20-1012
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGE5KX]
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)
Action code Not set Failure code Controller code DGE5KX Not set Trouble Failure in ambient temperature sensor system: Input signal outside range (KX)
Contents of trouble Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.

Problem that Ambient temperature cannot be monitored with monitoring function. appears on machine Related information
Ambient temperature can be checked with monitoring function (code: 37501). LED display is [n401] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-35. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. 0 C Between HM-35 (male) (1) (2) 20 C 50 C Resistance Approx. 10 15 kz Resistance Approx. 3 7 kz Resistance Approx. 1 3 kz
Defective ambient temperature sensor
1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-35. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (10) HM-35 (female) (1) Wiring harness between HM-CN2A (female) (12) HM-35 (female) (2) Resistance Max. 1 z Resistance Max. 1 z
1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-35. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (10) HM-35 (female) (1) Resistance between HMCN2A (female) (10), HM-35 Min. 1 Mz (female) (1) chassis ground
1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. 4 Defective VHMS controller Between HM-CN2A (female) (10) (12) 0 C 20 C 50 C Resistance Approx. 10 15 kz Resistance Approx. 3 7 kz Resistance Approx. 1 3 kz
HD465-7, HD605-7
20-1013
(10)
TROUBLESHOOTING
[DGT4KA]
[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Not set Failure code Controller code DGT4KA Not set Trouble Disconnection, short circuit with chassis ground in No. 1, 2, 3 (front) exhaust temperature sensor system (KA)
Contents of trouble Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.

Problem that No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function. appears on machine Related information
No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). LED display is [n312]. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 1, 2, 3 (front) exhaust temperature sensor. 1 Exhaust temperature sensor Defective No. 1, 2, 3 (front) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced 1) Turn starting switch OFF. 2) Disconnect connector HM-23A. 3) Insert T-adapter. Defective No. 1, 2, 3 (front) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) (C) HM-23A Between (B) (C) 20 C 500 C Exhaust temperature sensor defective
Voltage Voltage Voltage
20 30 V Approx. 0.9 1.2 V Approx. 2.6 3.5 V
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and HM-23A. 3) Connect T-adapter. Disconnection in wiring harness 3 (disconnection, defective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z HM-23A (female) (A) Wiring harness between HM-CN2A (female) (7) HM-23A (female) (B) Resistance Max. 1 z
Wiring harness between HM-22A (female) (1) Resistance Max. 1 z HM-21A (female) (1) Wiring harness between HM-22A (female) (2) Resistance Max. 1 z HM-21A (female) (2) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and HM-23A. 3) Connect T-adapter. Ground fault in wiring har4 ness Resistance between HMWiring harness between CN1 (female) (2), HM-23A HM-CN1 (female) (2) HM(female) (A) chassis 23A (female) (A) ground Wiring harness between HM-CN2A (female) (7) HM-23A (female) (B) Min. 1 Mz
Resistance between HMCN2A (female) (7), HM-23A Min. 1 Mz (female) (B) chassis ground
20-1014
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGT4KA]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) HM-CN2A (12) Between HM-CN2A (7) (12) 20 C 500 C Voltage Voltage Voltage 20 30 V Approx. 0.9 1.2V Approx. 2.6 3.5 V
Probable cause and standard value 5 Defective VHMS controller when normal
HD465-7, HD605-7
20-1015
(10)
TROUBLESHOOTING
[DGT4KB]
[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Not set Failure code Controller code DGT4KB Not set Trouble Short circuit with power source (Hot short) in No. 1, 2, 3 (front) exhaust temperature sensor system (KB)
Contents of trouble Signal voltage of more than 4.9V detected from No. 1, 2, 3 (front) exhaust temperature sensor.

Problem that No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function appears on machine Related information
No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). LED display is [n311] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 1, 2, 3 (front) exhaust temperature sensor 1 Exhaust temperature sensor Defective No. 1, 2, 3 (front) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced 1) Turn starting switch OFF. 2) Disconnect connector HM-23A. 3) Insert T-adapter. Defective No. 1, 2, 3 (front) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) (C) HM-23A Between (B) (C) 20 C 500 C Exhaust temperature sensor defective
Probable cause Ground fault in wiring harand standard value 3 ness when normal
1) Turn starting switch OFF. 2) Disconnect connectors HM-21A and HM-22A. 3) Connect T-adapter. Resistance between HMWiring harness between 22A (female) (1), HM-22A (female) (1) HMMin. 1 Mz HM-21A (female) (1) chas21A (female) (1) sis ground 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-23A. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (7) HM-23A (female) (B) Resistance between HMCN2 (female) (7), Min. 1 Mz HM-23A (female) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. Defective VHMS controller 5) Start engine. Between HM-CN1 (2) HM-CN2A (12) Between HM-CN2A (7) (12) 20 C 500 C Voltage Voltage Voltage 20 30 V Approx. 0.9 1.2 V Approx. 2.6 3.5 V
20-1016
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGT4KB]
HD465-7, HD605-7
20-1017
(2)
TROUBLESHOOTING
[DGT5KA]
[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Not set Failure code Controller code DGT5KA Not set Trouble Disconnection, short circuit with chassis ground in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA)
Contents of trouble Signal voltage of less than 0.3V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.

Problem that No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function appears on machine Related information
No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). LED display is [n322] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor 1 Exhaust temperature sensor Defective No. 4, 5, 6 (rear) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced 1) Turn starting switch OFF. 2) Disconnect connector HM-23B. 3) Insert T-adapter. Defective No. 4, 5, 6 (rear) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) (C) HM-23B Between (B) (C) 20 C 500 C Exhaust temperature sensor defective
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and HM-23B. 3) Connect T-adapter. Disconnection in wiring harness 3 (disconnection, defective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z HM-23B (female) (A) Wiring harness between HM-CN2A (female) (5) HM-23B (female) (B) Resistance Max. 1 z
Wiring harness between HM-22B (female) (1) Resistance Max. 1 z HM-21B (female) (1) Wiring harness between HM-22B (female) (2) Resistance Max. 1 z HM-21B (female) (2) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and HM-23B. 3) Connect T-adapter. Ground fault in wiring har4 ness Wiring harness between HM-CN1 (female) (2) HM-23B (female) (A) Wiring harness between HM-CN2A (female) (5) HM-23B (female) (B) Resistance between HMCN1 (female) (2), HM-23B (female) (A) chassis ground Min. 1 Mz
Resistance between HMCN2A (female) (5), HM-23B Min. 1 Mz (female) (B) chassis ground
20-1018
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGT5KA]
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) HM-CN2A (12) Between HM-CN2A (5) (12) 20 C 500 C Voltage Voltage Voltage 20 30 V Approx. 0.9 1.2 V Approx. 2.6 3.5 V
Probable cause and standard value 5 Defective VHMS controller when normal
HD465-7, HD605-7
20-1019
(10)
TROUBLESHOOTING
[DGT5KB]
[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Not set Failure code Controller code DGT5KB Not set Trouble Short circuit with power source (Hot short) in No. 4, 5, 6 (rear) exhaust temperature sensor system (KB)
Contents of trouble Signal voltage of more than 4.9V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.

Problem that No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function. appears on machine Related information
No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). LED display is [n321] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor 1 Exhaust temperature sensor Defective No. 4, 5, 6 (rear) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced 1) Turn starting switch OFF. 2) Disconnect connector HM-23B. 3) Insert T-adapter. Defective No. 4, 5, 6 (rear) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) (C) HM-23B Between (B) (C) 20 C 500 C Exhaust temperature sensor defective
Probable cause Ground fault in wiring harand standard value 3 ness when normal
1) Turn starting switch OFF. 2) Disconnect connectors HM-21B and HM-22B. 3) Connect T-adapter. Resistance between Wiring harness between HM-22B (female) (1), HM-22B (female) (1) HMHM-21B (female) (1) 21B (female) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-23B. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (5) HM-23B (female) (B) Resistance between HM-CN2 (female) (5), HM-23B (female) (B) chassis ground Min. 1 Mz Min. 1 Mz
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. Defective VHMS controller 5) Start engine. Between HM-CN1 (2) HM-CN2A (12) Between HM-CN2A (5) (12) 20 C 500 C Voltage Voltage Voltage 20 30 V Approx. 0.9 1.2 V Approx. 2.6 3.5 V
20-1020
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DGT5KB]
HD465-7, HD605-7
20-1021
(2)
TROUBLESHOOTING
[DHE5KB]
[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)
Action code Not set Failure code Controller code DHE5KB Not set Trouble Disconnection, short circuit with chassis ground in engine blowby pressure sensor system (KA)
Contents of trouble Signal voltage of blow-by pressure sensor has dropped below 0.1V.

Problem that Blow-by pressure cannot be monitored with monitoring function. appears on machine Related information
Blow-by pressure can be checked with monitoring function (code: 42800). LED display is [n332] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-12. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-12 (B) (A) Between HM-12 (C) (A) Voltage Voltage 4.5 5.5V 0.3 0.7V
Defective engine blow-by pressure sensor
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12. Disconnection in wiring har- 3) Connect T-adapter. 2 ness (disconnection, defec- Wiring harness between HM-CN1 (female) Resistance Max. 1 z tive contact) (4),(5) HM-12 (female) (B) Wiring harness between HM-CN2A (female) (18) HM-12 (female) (C) Probable cause and standard value when normal Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12. 3) Connect T-adapter. Ground fault in wiring harness Wiring harness between HM-CN1 (female) (4),(5) HM-12 (female) (B) Wiring harness between HM-CN2A (female) (18) HM-12 (female) (C) Resistance between HMCN1 (female) (4),(5), HM-12 Min. 1 Mz (female) (B) chassis ground Resistance between HMCN2A (female) (18), HM-12 Min. 1 Mz (female) (C) - chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (5) HM-CN2A (12) Between HM-CN2A (18) (12) Voltage Voltage 4.5 5.5V 0.3 0.7V
20-1022
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DHE5KY]
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)
Action code Not set Failure code Controller code DHE5KY Not set Trouble Short circuit with power source (Hot short) in engine blow-by pressure sensor system (KY)
Contents of trouble Signal voltage of blow-by pressure sensor has risen above 4.7V.

Problem that Blow-by pressure cannot be monitored with monitoring function. appears on machine Related information
Blow-by pressure can be checked with monitoring function (code: 42800). LED display is [n331] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-12. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-12 (B) (A) Between HM-12 (C) (A) Voltage Voltage 4.5 5.5 V 0.3 0.7 V
Defective engine blow-by pressure sensor
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-12. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (18) HM-12 (female) (C) Voltage between HM-CN2A (female)(18), HM-12 (female) (C) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Connect T-adapter. Between HM-CN1 (5) HMCN2A (12) Between HM-CN2A (18) (12) Voltage Voltage 4.5 5.5 V 0.3 0.7 V
HD465-7, HD605-7
20-1023
(10)
TROUBLESHOOTING
[DhP4KX]
[DhP4KX]
SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIGNAL RANGE (KX)
Failure code Controller code DhP4KX PLM Trouble Suspension pressure sensor (Front right): Out of input signal range (KX)
Action code E01

Contents of trouble
The voltage of the signal circuit of the suspension pressure sensor (Front right) is below 0.3 V or above 4.9 V.

Problem that The payload is not indicated and saved correctly. appears on machine Related information
The suspension pressure (Front right) signal can be checked with the monitoring function (Code: 32804). This failure occurs only when the built-in PLM function is installed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (1) SUFR (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z SUFR (female) (B) Wiring harness between HM-CN2B (female) (9) SUFR (female) (A) Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR. 3) Connect T-adapter. Wiring harness between HM-CN2B (female) (1) SUFR (female) (C) Wiring harness between HM-CN1 (female) (2) SUFR (female) (B) Resistance between HMCN2B (female) (1), SUFR (female) (C) chassis ground Resistance between HMCN1 (female) (2), SUFR (female) (B) chassis ground Min. 1 M z
Min. 1 M z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SUFR. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (1) SUFR (female) (C) Voltage between HM-CN2B (female) (1), SUFR (female) (C) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector SUFR. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Front right) 5) Turn starting switch ON. Between SUFR (B) (A) Between SUFR (C) (A) Voltage Voltage 20 30 V 1.0 4.6 V
Defective VHMS & PLM controller
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2B. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN1 (2) HM-CN2B (9) Between HM-CN2B (1) (9) Voltage Voltage 20 30 V 1.0 4.6 V
20-1023-1
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DhP4KX]
HD465-7, HD605-7
20-1023-2
(5)
TROUBLESHOOTING
[DhP5KX]
[DhP5KX]
SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIGNAL RANGE (KX)
Failure code Controller code DhP5KX PLM Trouble Suspension pressure sensor (Front left): Out of input signal range (KX)
Action code E01

Contents of trouble
The voltage of the signal circuit of the suspension pressure sensor (Front left) is below 0.3 V or above 4.9 V.

The suspension pressure (Front left) signal can be checked with the monitoring function (Code: 32805). This failure occurs only when the built-in PLM function is installed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (2) SUFL (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z SUFL (female) (B) Wiring harness between HM-CN2B (female) (9) SUFL (female) (A) Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL. 3) Connect T-adapter. Ground fault in wiring har2 ness Wiring harness between HM-CN2B (female) (2) SUFL (female) (C) Wiring harness between HM-CN1 (female) (2) SUFL (female) (B) Resistance between HMCN2B (female) (2), SUFL (female) (C) chassis ground Min. 1 M z
Resistance between HMCN1 (female) (2), SUFL (fe- Min. 1 M z male) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SUFL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (2) SUFL (female) (C) Voltage between HM-CN2B (female) (2), SUFL (female) (C) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector SUFL. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Front left) 5) Turn starting switch ON. Between SUFL (B) (A) Between SUFL (C) (A) Voltage Voltage 20 30 V 1.0 4.6 V
20-1023-3
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DhP5KX]
HD465-7, HD605-7
20-1023-4
(5)
TROUBLESHOOTING
[DhP6KX]
[DhP6KX]
SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIGNAL RANGE (KX)
Failure code Controller code DhP6KX PLM Trouble Suspension pressure sensor (Rear right): Out of input signal range (KX)
Action code E01

Contents of trouble
The voltage of the signal circuit of the suspension pressure sensor (Rear right) is below 0.3 V or above 4.9 V.

The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32806). This failure occurs only when the built-in PLM function is installed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURR. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (7) SURR (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z SURR (female) (B) Wiring harness between HM-CN2B (female) (9) SURR (female) (A) Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURR. 3) Connect T-adapter. Wiring harness between HM-CN2B (female) (7) SURR (female) (C) Wiring harness between HM-CN1 (female) (2) SURR (female) (B) Resistance between HMCN2B (female) (7), SURR (female) (C) chassis ground Resistance between HMCN1 (female) (7), SURR (female) (B) chassis ground Min. 1 M z
Min. 1 M z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SURR. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (7) SURR (female) (C) Voltage between HM-CN2B (female) (7), SURR (female) (C) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector SURR. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Rear right) 5) Turn starting switch ON. Between SURR (B) (A) Between SURR (C) (A) Voltage Voltage 20 30 V 1.0 4.6 V
20-1023-5
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DhP6KX]
HD465-7, HD605-7
20-1023-6
(5)
TROUBLESHOOTING
[DhP7KX]
[DhP7KX]
SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL RANGE (KX)
Failure code Controller code DhP7KX PLM Trouble Suspension pressure sensor (Rear right): Out of input signal range (KX)
Action code E01

Contents of trouble
The voltage of the signal circuit of the suspension pressure sensor (Rear left) is below 0.3 V or above 4.9 V.

The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32807). This failure occurs only when the built-in PLM function is installed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURL. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (8) SURL (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z SURL (female) (B) Wiring harness between HM-CN2B (female) (9) SURL (female) (A) Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURL. 3) Connect T-adapter. Ground fault in wiring har2 ness Wiring harness between HM-CN2B (female) (8) SURL (female) (C) Wiring harness between HM-CN1 (female) (2) SURL (female) (B) Resistance between HMCN2B (female) (8), SURL (female) (C) chassis ground Min. 1 M z
Resistance between HMCN1 (female) (2), SURL (fe- Min. 1 M z male) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SURL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (8) SURL (female) (C) Voltage between HM-CN2B (female) (8), SURL (female) (C) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector SURL. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Rear left) 5) Turn starting switch ON. Between SURL (B) (A) Between SURL (C) (A) Voltage Voltage 20 30 V 1.0 4.6 V
20-1023-7
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DhP7KX]
HD465-7, HD605-7
20-1023-8
(5)
TROUBLESHOOTING
[DKH1KX]
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code E01 Failure code Controller code DKH1KX PLM Trouble Pitch angle sensor: Out of input signal range (KX)
Contents of trouble The voltage of the signal circuit of the pitch angle sensor is below 0.3 V or above 4.9 V.

The pitch angle sensor signal [Angle (rad.)] can be checked with the monitoring function (Code: 32901). This failure occurs only when the built-in PLM function is installed. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and PM3. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (3) PM3 (female) (B) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z PM3 (female) (C) Wiring harness between HM-CN2B (female) (9) PM3 (female) (A) 1) Turn starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between HM-CN2B (female) (3) PM3 (female) (B) Wiring harness between HM-CN1 (female) (2) PM3 (female) (C) Resistance between HMCN2B (female) (3), PM3 (fe- Min. 1 M z male) (B) chassis ground Resistance between HMCN1 (female) (2), PM3 (female) (C) chassis ground Min. 1 M z Resistance Max. 1 z
1) Turn starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (3) PM3 (female) (B) Voltage between HM-CN2B (female) (3), MP3 (female) (B) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connectors PM3. 3) Insert connect T-adapter. 4 Defective pitch angle sensor 4) Connect connector. 5) Turn starting switch ON. Between PM3 (C) (A) Between PM3 (B) (A) Voltage Voltage 20 30 V 1.0 4.6 V
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2B 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN1 (2) HM-CN2B (9) Between HM-CN2B (3) (9) Voltage Voltage 20 30 V 1.0 4.6 V
20-1023-9
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DKH1KX]
HD465-7, HD605-7
20-1023-10
(6)
TROUBLESHOOTING
[F@BBZL]
[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)
Action code Not set Failure code Controller code F@BBZL Not set Trouble Engine blow-by pressure is high: (ZL)
Contents of trouble Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.

Blow-by pressure can be checked with monitoring function (code: 42800). LED display is [n338] Related information If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable code. Cause Probable cause and standard value Defective orifice inside when normal 2 breather Abnormal rise in blow-by 1 pressure Standard value in normal state/Remarks on troubleshooting Inspect engine and repair if any abnormality is found Inspect orifice inside breather and repair if any abnormality is found If Items 1 and 2 are normal, defective VHMS controlle
20-1024
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[F@BYNR]
[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)
Action code Not set
Contents of trouble
Failure code Controller code F@BYNR Not set
Trouble No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)
Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust temperature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750 C at more than rated output speed and 800 C at less than max. torque speed)

No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600) LED display is [n362] Related information If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 1, 2, 3 1 (front) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller Standard value in normal state/Remarks on troubleshooting
Inspect engine and repair if any abnormality is found
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) HM-CN2A (12) Between HM-CN2A (7) (12) 20 C 500 C Voltage Voltage Voltage 20 30 V Approx. 0.9 1.2 V Approx. 2.6 3.5 V
HD465-7, HD605-7
20-1025
(10)
TROUBLESHOOTING
[F@BYNS]
[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)
Action code Not set
Contents of trouble
Failure code Controller code F@BYNS Not set
Trouble No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)
Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust temperature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700 C at more than rated output speed and 750 C at less than max. torque speed)

No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). LED display is [n361] Related information If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 1, 2, 3 1 (front) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller Standard value in normal state/Remarks on troubleshooting
20-1026
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[F@BZNR]
[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR)
Action code Not set
Contents of trouble
Failure code Controller code F@BZNR Not set
Trouble No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)
Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust temperature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750 C at more than rated output speed and 800 C at less than max. torque speed)

No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). LED display is [n372] Related information If failure codes [DGT5KA] or [DGT5KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 4, 5, 6 1 (rear) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller Standard value in normal state/Remarks on troubleshooting
HD465-7, HD605-7
20-1027
(10)
TROUBLESHOOTING
[F@BZNS]
[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS)
Action code Not set
Contents of trouble
Failure code Controller code F@BZNS Not set
Trouble No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)
Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust temperature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700 C at more than rated output speed and 750 C at less than max. torque speed)

No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). LED display is [n371] Related information If failure codes [DGT5KA] or [DGT5KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 4, 5, 6 1 (rear) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller Standard value in normal state/Remarks on troubleshooting
20-1028
(10)
HD465-7, HD605-7
TROUBLESHOOTING
VHMS-1
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION

a) Satellite communication data are not transmitted
Action code Not set Failure code Controller code Not set Not set Trouble Abnormality in satellite data communication a) Satellite communication data are not transmitted
Contents of trouble Satellite communication data are not transmitted.

Problem that Satellite communication data are not transmitted. appears on machine Related information
Cause 1
Machine is in tunnel or build- Not defective. ing aMove the machine outdoors.
Machine is behind building Not defective. 2 or mountain and only a part aMove the machine to a place from where you can look out over the of heaven is seen from it heavens. 3 Abnormality in communica- Check communication antenna. If it is broken or removed, repair or tion antenna replace it. Check inside of communication antenna and remove foreign matter.
Entry of foreign matter in 4 communication antenna connector 5
Abnormality in communica- Check communication antenna. If it is broken (or disconnected), retion antenna cable pair or replace it. 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Connect T-adapter. Wiring harness between ORB-B (female) (1) Resistance Max. 1 z HM-CN4B (female) (4)
Wiring harness between ORB-B (female) (2) Probable cause Resistance Max. 1 z Disconnection in wiring har- HM-CN4B (female) (10) and standard value 6 ness (Disconnection or deWiring harness between ORB-B (female) (3) when normal Resistance Max. 1 z fective contact) HM-CN4B (female) (3) Wiring harness between ORB-A (female) (7), Resistance Max. 1 z (8) HM-CN1 (female) (6), (7) Wiring harness between ORB-A (female) (10), Resistance Max. 1 z (11) HM-CN1 (female) (19), (20) Wiring harness between ORB-A (female) (2) Resistance Max. 1 z HM-CN2 (female) (17) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Connect T-adapter. Wiring harness between ORB-B (female) (1) HMGround fault or short circuit CN4B (female) (4) 7 in wiring harness Wiring harness between ORB-B (female) (2) HMCN4B (female) (10) Wiring harness between ORB-B (female) (3) HMCN4B (female) (3) Resistance between ORB-B (female) (1), HM-CN4B (fe- Min. 1M z male) (4) chassis ground Resistance between ORB-B (female) (2), HM-CN4B (fe- Min. 1M z male) (10) chassis ground Resistance between ORB-B (female) (3), HM-CN4B (fe- Min. 1M z male) (3) chassis ground
HD465-7, HD605-7
20-1029
(10)
TROUBLESHOOTING
VHMS-1
Cause
Standard value in normal state/Remarks on troubleshooting Wiring harness between ORB-A (female) (7), (8) HM-CN1 (female) (6), (7) Resistance between ORB-A (female) (7), (8), HM-CN1 Min. 1M z (female) (6), (7) chassis ground
Resistance between ORB-A Wiring harness between (female) (10), (11), HM-CN1 ORB-A (female) (10), (11) Min. 1M z (female) (19), (20) chassis HM-CN1 (female) (19), (20) ground Wiring harness between ORB-A (female) (2) HMCN2A (female) (17) Wiring harness between ORB-B (female) (1) HMCN4B (female) (4) and between ORB-B (female) (2) HM-CN4B (female) (10) Wiring harness between ORB-B (female) (1) HMGround fault or short circuit CN4B (female) (4) and be7 in wiring harness tween ORB-B (female) (3) HM-CN4B (female) (3) Wiring harness between ORB-B (female) (2) HMCN4B (female) (10) and between ORB-B (female) (3) HM-CN4B (female) (3) Wiring harness between ORB-A (female) (7), (8) HM-CN1 (female) (6), (7) and between ORB-A (female) (10), (11) HM-CN1 (female) (19), (20) Wiring harness between ORB-A (female) (2) HMCN2A (female) (17) and between ORB-A (female) (10), (11) HM-CN1 (female) (19), (20) Resistance between ORB-A (female) (2), HM-CN2A (fe- Min. 1M z male) (17) chassis ground Resistance between ORB-B (female) (1) HM-CN4B (female) (4) and between ORB- Min. 1M z B (female) (2) HM-CN4B (female) (10) Resistance between ORB-B (female) (1) HM-CN4B (female) (4) and between ORB- Min. 1M z B (female) (3) HM-CN4B (female) (3) Resistance between ORB-B (female) (2) HM-CN4B (female) (10) and between Min. 1M z ORB-B (female) (3) HMCN4B (female) (3) Resistance between ORB-A (female) (7), (8) HM-CN1 (female) (6), (7) and beMin. 1M z tween ORB-A (female) (10), (11) HM-CN1 (female) (19), (20) Resistance between ORB-A (female) (2) HM-CN2A (female) (17) and between Min. 1M z ORB-A (female) (10), (11) HM-CN1 (female) (19), (20)
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON.
20-1030
(10)
HD465-7, HD605-7
TROUBLESHOOTING
VHMS-1
Cause
Standard value in normal state/Remarks on troubleshooting Wiring harness between ORB-B (female) (1) HMCN4B (female) (4) Wiring harness between ORB-B (female) (2) HMCN4B (female) (10) Wiring harness between ORB-B (female) (3) HMCN4B (female) (3) Wiring harness between ORB-A (female) (2) HMCN2A (female) (17) Voltage between ORB-B (female) (1), HM-CN4B (female) (4) chassis ground Voltage between ORB-B (female) (2), HM-CN4B (female) (10) chassis ground Voltage between ORB-B (female) (3), HM-CN4B (female) (3) chassis ground Voltage between ORB-A (female) (2), HM-CN2A (female) (17) chassis ground Max. 1 V
Max. 1 V
Max. 1 V
Max. 1 V
1) Turn starting switch ON. About 3 minutes after the VHMS controller is turned ON, judge by the state of the decimal point of the VHMS controller LED (7 segments on the right side). Decimal point goes off VHMS controller cannot communicate with ORBCOMM controller (Abnormality in ORBCOMM controller).
Defective ORBCOMM con Communication with VHMS is normal. troller Decimal point lights up ORBCOMM controller does not have data to transmit. Communication with VHMS is normal. Decimal point flashes ORBCOMM controller has data to transmit quickly and has captured satellite (is transmitting). Communication with VHMS is normal. Decimal point flashes ORBCOMM controller has data to transmit slowly but has not captured satellite.
HD465-7, HD605-7
20-1031
(10)
TROUBLESHOOTING
VHMS-1
b) Abnormality in downloading into PC or setting of PC

Action code Not set Failure code Controller code Not set Not set Abnormality in satellite data communication b) Abnormality in downloading into PC or setting of PC
Trouble
Contents of trouble PC cannot download or cannot be set.

Problem that PC cannot download or cannot be set. appears on machine Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN4A and VHMS. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (9) VHMS (female) (B) Wiring harness between HM-CN4A (female) (10) VHMS (female) (C) Wiring harness between HM-CN4A (female) (11) VHMS (female) (D) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
Disconnection in wiring harness (Disconnection or de1 fective contact) aWiring harness for downloading in cab
1) Turn starting switch OFF. 2) Disconnect connectors HM-CN4A and VHMS. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (9) VHMS (female) (B) Wiring harness between HM-CN4A (female) (10) VHMS (female) (C) Wiring harness between HM-CN4A (female) (11) Ground fault or short circuit VHMS (female) (D) in wiring harness 2 aWiring harness for down- Wiring harness between loading inside cab HM-CN4A (female) (9) Resistance between HMCN4A (female) (9), VHMS (female) (B) chassis ground Min. 1M z
Resistance between HMCN4A (female) (10), VHMS Min. 1M z (female) (C) chassis ground Resistance between HMCN4A (female) (11), VHMS (female) (D) chassis ground Min. 1M z
Resistance between HMCN4A (female) (9) VHMS VHMS (female) (B) and be- (female) (B) and between Min. 1M z tween HM-CN4A (female) HM-CN4A (female) (10) (10) VHMS (female) (C) VHMS (female) (C) Wiring harness between HM-CN4A (female) (9) VHMS (female) (B) and between HM-CN4A (female) (11) VHMS (female) (D) Wiring harness between HM-CN4A (female) (10) VHMS (female) (C) and between HM-CN4A (female) (11) VHMS (female) (D) Resistance between HMCN4A (female) (9) VHMS (female) (B) and between Min. 1M z HM-CN4A (female) (11) VHMS (female) (D) Resistance between HMCN4A (female) (10) VHMS (female) (C) and between Min. 1M z HM-CN4A (female) (11) VHMS (female) (D)
20-1032
(10)
HD465-7, HD605-7
TROUBLESHOOTING
VHMS-1
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors VHMS and VDL. 3) Connect T-adapter. Wiring harness between VHMS (male) (B) VDL (female) (B) Wiring harness between VHMS (male) (C) VDL (female) (C) Wiring harness between VHMS (male) (D) VDL (female) (D) 1) Turn starting switch OFF. 2) Disconnect connectors VHMS and VDL. 3) Connect T-adapter. Wiring harness between Resistance between VHMS VHMS (male) (B) VDL (fe- (male) (B) VDL (female) Min. 1M z male) (B) (B) chassis ground Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
Disconnection in wiring harness (Disconnection or de3 fective contact) aWiring harness for downloading inside cab
Wiring harness between Resistance between VHMS VHMS (male) (C) VDL (fe- (male) (C) VDL (female) Min. 1M z male) (C) (C) chassis ground Wiring harness between Resistance between VHMS VHMS (male) (D) VDL (fe- (male) (D) VDL (female) Min. 1M z male) (D) (D) chassis ground Resistance between VHMS (male) (B) VDL (female) (B) and between VHMS Min. 1M z (male) (C) VDL (female) (C) Resistance betweenVHMS (male) (B) VDL (female) (B) and between VHMS (male) (D) VDL (female) (D)
Ground fault or short circuit Wiring harness between in wiring harness 4 aWiring harness for down- VHMS (male) (B) VDL (female) (B) and between loading outside cab VHMS (male) (C) VDL (female) (C) Wiring harness between VHMS (male) (B) VDL (female) (B) and between VHMS (female) (D) VDL (male) (D)
Min. 1M z
Wiring harness between VHMS (male) (C) VDL (female) (C) and between VHMS (male) (D) VDL (female) (D)
Resistance between VHMS (male) (C) VDL (female) (C) and between VHMS Min. 1M z (male) (D) VDL (female) (D)
HD465-7, HD605-7
20-1033
(10)
TROUBLESHOOTING
VHMS-2
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)
Action code Not set
Contents of trouble
Abnormality in saving data in VHMS controller Trouble (Data are not saved) a LED of VHMS counts up and operates normally
Data are not saved in the VHMS controller. aPower is kept turned off.

Problem that None in particular. appears on machine Related information
If fuse BT-2 (29) is broken, check the wiring harness between fuse and HM-CN1 (6), (7) for grounding fault. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-CN1 and fuse terminal BT-2 (29). 3) Connect T-adapter.
Wiring harness between HM-CN1 (female) (6), Resistance Max. 1 z Probable cause (7) fuse terminal BT-2 (29) Disconnection in wiring harand standard value 1 ness (Disconnection or de- *1) After the starting switch is turned to the OFF position, the LED of when normal the VHMS displays SH (Processing time of memory), and then the fective contact) all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. *2) If the power for the VHMS is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.
20-1034
(10)
HD465-7, HD605-7
TROUBLESHOOTING
VHMS-2
HD465-7, HD605-7
20-1035
(5)
TROUBLESHOOTING
VHMS-3
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL)
Action code Not set Failure code Controller code Not set Not set Engine blow-by pressure indicated by monitor is low Trouble (When blow-by pressure measured with measuring instrument is normal)
Contents of trouble The engine blow-by pressure indicated by the monitor is low.
Action of controller None in particular. The engine blow-by pressure indicated by the monitor is low. Problem that appears on machine (The blow-by pressure measured with a measuring instrument is normal.)
Related information
The blow-by pressure can be checked with the monitoring function (Code: 42800). If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
Cause Standard value in normal state/Remarks on troubleshooting Probable cause and standard value 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal. when normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.
20-1036
(10)
HD465-7, HD605-7
TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE)
Electrical system diagram related ASR control ........................................................................................ 20-1052 Information in troubleshooting table...................................................................................................... 20-1053 Phenomenon code table....................................................................................................................... 20-1054 [DDDAKA] ASR system switch system: Disconnection (KA).............................................................. 20-1055 [DDDAKB] ASR system switch system: Short circuit (KB) ................................................................. 20-1056 [DK30KX] Steering angle sensor: Out of input signal range (KX) .................................................... 20-1057 [DLF8KA] Wheel speed sensor (RR): Disconnection (KA) ............................................................... 20-1059 [DLF8LC] Wheel speed sensor (RR): *See separate list (LC) ......................................................... 20-1060 [DLF9KA] Wheel speed sensor (RL): Disconnection (KA) ................................................................ 20-1061 [DLF9LC] Wheel speed sensor (RL): *See separate list (LC)........................................................... 20-1062 [dLT3LC] Transmission output shaft speed sensor: *See separate list (LC) ................................... 20-1063 [DWNBK4] Shut-off solenoid valve: Uncontrollable (K4) .................................................................... 20-1065 [DWNBKA] Shut-off solenoid valve: Disconnection (KA) .................................................................... 20-1067 [DWNBKB] Shut-off solenoid valve: Short circuit (KB) ....................................................................... 20-1068 [DWNBKY] Shut-off solenoid valve: Short circuit with power source (Hot short) (KY) ........................ 20-1069 [DWNBMA] Shut-off solenoid valve: Malfunction (MA) ........................................................................ 20-1070 [DX17K4] ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4) ............ 20-1071 [DX17KA] ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA) ............ 20-1073 [DX17KB] ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)................ 20-1074 [DX17KY] ASR proportional solenoid pressure reducing valve (Right): Short circuit with power source (Hot short) (KY).......................................................................................... 20-1075 [DX17MA] ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)................ 20-1076 [DX18K4] ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4) .............. 20-1077 [DX18KA] ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA) .............. 20-1079 [DX18KB] ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB) .................. 20-1080 [DX18KY] ASR proportional solenoid pressure reducing valve (Left): Short circuit with power source (Hot short) (KY).......................................................................................... 20-1081 [DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082
HD465-7, HD605-7
20-1051
(10)
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
20-1052
(5)
HD465-7, HD605-7
TROUBLESHOOTING

Contents of trouble Condition at the time when the monitor panel or controller detects the trouble
The action taken by the monitor panel or controller to protect the system or devices when the monitorpanel or controller detects the trouble
The problem that appears on the machine as a result of the action taken by the monitor panel or controller Problem that appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting
Cause
Possible causes 3 Possible causes of trouble <Precautions for troubleshooting> and standard value (Given numbers are refer- 1) Method of indicating connector No. and handling of Tin normal state ence numbers, which do not adapter indicate priority) Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.

4 If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side.
2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified.
5 Connect positive (+) lead to pin No. or harness entered on front side. Connect negative () lead to pin No. or harness entered on rear side.
HD465-7, HD605-7
20-1053
(10)
TROUBLESHOOTING
This a circuit diagram of the part related to the failure. Connector No.: Shows the "Type Number of pin" and " Color". Arrow ( ): Roughly shows the location on the machine.

20-1054
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DDDAKA]
[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Action code E01 Failure code Controller code DDDAKA BK Trouble ASR system switch system: Disconnection (KA)
Contents of trouble The ASR system switch ON input and system switch OFF input are turned OFF.
Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch can be checked with the monitoring function (Code: 37900).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter.
Wiring harness between DPC2B (female) (3) Resistance Max. 1 z ASR (female) (3) 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter. Wiring harness between DPC2B (female) (9) Resistance Max. 1 z ASR (female) (3)
Possible causes and standard value Defective ASR system 2 in normal state switch
1) Turn starting switch OFF. 2) Replace ASR system switch with normal one. 3) Turn starting switch ON. When ASR system switch is replaced with normal one, does condition become normal? 1) Turn starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Yes No System switch is normal System switch is defective
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON chassis ground ASR system switch OFF Between DPC2B (9) ASR system switch ON chassis ground ASR system switch OFF
20 30 V Max. 1 V Max. 1 V 20 30 V
HD465-7, HD605-7
20-1055
(10)
TROUBLESHOOTING
[DDDAKB]
[DDDAKB] ASR SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Action code E01 Failure code Controller code DDDAKB BK Trouble ASR system switch system: Short circuit (KB)
Contents of trouble The ASR system switch ON input and system switch OFF input are turned ON.
Related information The state of the ASR switch can be checked with the monitoring function (Code: 37900).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter. 4) Turn starting switch ON.
Wiring harness between DPC2B (female) (3) ASR (female) (3) Wiring harness between DPC2B (female) (9) ASR (female) (2)
Voltage between DPC2B (female) (3), ASR (female) (3) Max. 1 V chassis ground Voltage between DPC2B (female) (9), ASR (female) (2) Max. 1 V chassis ground
Possible causes Defective ASR system and standard value 2 switch in normal state
1) Turn starting switch OFF. 2) Replace ASR system switch with normal one. 3) Turn starting switch ON. When ASR system switch is replaced with normal one, does condition become normal? 1) Turn starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Yes No System switch is normal System switch is defective
Between DPC2B (3) ASR system switch ON chassis ground ASR system switch OFF Between DPC2B (9) ASR system switch ON chassis ground ASR system switch OFF
20 30 V Max. 1 V Max. 1 V 20 30 V
20-1056
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DK30KX]
[DK30KX] STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code E01 Failure code Controller code DK30KX BK Trouble Steering angle sensor: Out of input signal range (KX)
Contents of trouble The voltage of the signal circuit of the steering angle sensor is below 0.5 V or above 4.7 V.
Action of controller Controls the ASR by setting the steering angle (turning angle) to 20 degrees.
Problem that The machine is not affected badly. appears on machine Related information The steering angle can be checked with the monitoring function (Code: 35400).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter.
Disconnection in wiring Wiring harness between BRC2 (female) (16) Resistance Max. 1 z harness ASR1 (female) (3) 1 (Disconnection or defective Wiring harness between BRC3A (female) (7) contact) Resistance Max. 1 z ASR1 (female) (2) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z ASR1 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter. 2 Ground fault in wiring harness Resistance between BRC2 Wiring harness between BRC2 (female) (16) ASR1 (female) (16), ASR 1 (female) Min. 1 Mz (female) (3) (3) chassis ground Resistance between BRC3A Wiring harness between BRC3A (female) (7) ASR1 (female) (7), ASR1 (female) Min. 1 Mz (female) (2) (2) chassis ground Possible causes and standard value in normal state 3 Hot short in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Voltage between BRC2 Wiring harness between BRC2 (female) (16) ASR1 (female) (16), ASR1 (female) (female) (3) (3) chassis ground Voltage between BRC3A Wiring harness between BRC3A (female) (7) ASR1 (female) (7), ASR1 (female) (female) (2) (2) chassis ground 1) Turn starting switch OFF. 2) Disconnect connector RTL. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR1 (3) (1) Between ASR1 (2) (1) 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and RTL. 3) Insert connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON. Between BRC1 (16) BRC3A (16) Between BRC3A (7) (16) Voltage Voltage 4.6 5.4 V 23V Voltage Voltage 4.6 5.4 V 23V Max. 1 V
Max. 1 V
Defective steering angle sensor
HD465-7, HD605-7
20-1057
(10)
TROUBLESHOOTING
[DK30KX]
20-1058
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF8KA]
[DLF8KA] WHEEL SPEED SENSOR (RR): DISCONNECTION (KA)

Action code E01 Failure code Controller code DLF8KA BK Trouble Wheel speed sensor (RR): Disconnection (KA)
Contents of trouble The signal circuit of the wheel speed sensor (RR) is disconnected and signals are not input.
Related information The wheel speed (RR) can be checked with the monitoring function (Code: 39701).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRR. 3) Connect T-adapter. Between WSRR (male) (1) (2) Between WSRR (male) (1), (2) chassis ground Resistance 950 1,450 z Resistance Min. 1 Mz
Defective wheel speed sensor (RR)
Disconnection in wiring harness 2 Wiring harness between BRC3A (female) (3) Resistance Max. 1 z (Disconnection or defective WSRR (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z WSRR (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC3A. Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) (14) Resistance 950 1,450 z
1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Connect T-adapter.
HD465-7, HD605-7
20-1059
(10)
TROUBLESHOOTING
[DLF8LC]
[DLF8LC] WHEEL SPEED SENSOR (RR): *SEE SEPARATE LIST (LC)

Action code E01
Contents of trouble
Failure code Controller code DLF8LC BK
Trouble Wheel speed sensor (RR): *See separate list (LC)
The wheel speed (RR) calculated from the transmission output shaft speed sensor signal and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor.
Related information The wheel speed (RR) can be checked with the monitoring function (Code: 39701).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRR. 3) Connect T-adapter. Between WSRR (male) (1) (2) Between WSRR (male) (1), (2) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Connect T-adapter. Wiring harness between BRC3A (female) (3) WSRR (female) (1) Resistance between BRC3A (female) (3), WSRR (female) Min. 1 Mz (1) chassis ground Resistance 950 1,450 z Resistance Min. 1 Mz
Defective wheel speed sensor (RR)
1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC3A (female) (3) WSRR (female) (1) Voltage between BRC3A (female) (3), WSRR (female) (1) chassis ground Max. 1 V
1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 4 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) (14) Resistance 950 1,450 z
20-1060
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF9KA]
[DLF9KA] WHEEL SPEED SENSOR (RL): DISCONNECTION (KA)

Action code E01 Failure code Controller code DLF9KA BK Trouble Wheel speed sensor (RL): Disconnection (KA)
Contents of trouble The signal circuit of the wheel speed sensor (RL) is disconnected and signals are not input.
Related information The wheel speed (RL) can be checked with the monitoring function (Code: 39700).
Cause
1) Turn starting switch OFF. 2) Disconnect connector WSRL. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (RL) Between WSRL (male) (1) (2) Between WSRL (male) (1), (2) chassis ground Possible causes and standard value in normal state 1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Connect T-adapter.
Resistance 950 1,450 z Resistance Min. 1 Mz
Disconnection in wiring harness 2 Wiring harness between BRC3A (female) (2) (Disconnection or defective Resistance Max. 1 z WSRL (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z WSRL (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 3 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) (14) Resistance 950 1,450 z
HD465-7, HD605-7
20-1061
(10)
TROUBLESHOOTING
[DLF9LC]
[DLF9LC] WHEEL SPEED SENSOR (RL): *SEE SEPARATE LIST (LC)

Action code E01
Contents of trouble
Failure code Controller code DLF9LC BK
Trouble Wheel speed sensor (RL): *See separate list (LC)
The wheel speed (RL) calculated from the transmission output shaft speed sensor signal and wheel (RR) speed sensor signal is different from the signal speed of the wheel (RL) speed sensor.
Related information The wheel speed (RL) can be checked with the monitoring function (Code: 39700).
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRL. 3) Connect T-adapter. Between WSRL (male) (1) (2) Between WSRL (male) (1), (2) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Connect T-adapter. Resistance between BRC3A Wiring harness between BRC3A (female) (3) WSRL (female) (3), WSRL (female) Min. 1 Mz (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Voltage between BRC3A Wiring harness between BRC3A (female) (3) WSRL (female) (3), WSRL (female) (female) (1) (1) chassis ground Max. 1 V Resistance 950 1,450 z Resistance Min. 1 Mz
Defective wheel speed sensor (RL)
1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 4 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (2) (14) Resistance 950 1,450 z
20-1062
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[dLT3LC]
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)
Action code E01 Failure code Controller code dLT3LC BK Trouble Transmission output shaft speed sensor: *See separate list (LC) (ASR is set and ASR system switch is turned ON)
The travel speed calculated from the transmission output shaft speed sensor signal, wheel (RR) speed Contents of trouble sensor signal, and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor and wheel (RL) speed sensor. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
The transmission output shaft speed can be checked with the monitoring function (Code: 31400). The wheel speed can be checked with the monitoring function (Code: 39700, 39701). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) (2) Resistance 500 1,000 z Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5. 3) Connect T-adapter. 2 Ground fault in wiring harness Wiring harness between ATC3A (female) (3) BRC3A (female) (13) PM5 (female) (7) CN5 (female) (1) Resistance between BRC3A (female) (13), ATC3A (female) Min. 1 Mz (3), PM5 (female) (7), CN5 (female) (1) chassis ground
Defective transmission output shaft speed sensor
1) Turn starting switch OFF. 2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between ATC3A (female) (3) BRC3A (female) (13) PM5 (female) (7) CN5 (female) (1) Voltage between ATC3A (female) (3), BRC3A (female) (13), PM5 (female) (7), CN5 (female) (1) chassis ground
Max. 1 V
1) Turn starting switch OFF. Defective transmission con- 2) Disconnect connector BRC3A. 4 3) Connect T-adapter. troller Between BRC3A (female) (13) (14)
HD465-7, HD605-7
20-1063
(10)
TROUBLESHOOTING
[dLT3LC]
20-1064
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNBK4]
[DWNBK4] SHUT-OFF SOLENOID VALVE: UNCONTROLLABLE (K4)

Action code E01 Failure code Controller code DWNBK4 BK Trouble Shut-off solenoid valve: Uncontrollable (K4)
Contents of trouble The shut-off solenoid valve does not return (does not move) or the pressure switch system is defective.
Related information
Cause 1 Defective shut-off solenoid valve
Standard value in normal state/Remarks on troubleshooting Check the shut-off solenoid valve and repair or replace it, if it has abnormality (mechanical failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Resistance between BRC5B Wiring harness between BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Voltage between BRC5B BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) (female) (1) (1) chassis ground Max. 1 V Max. 1 z
Defective shut-off solenoid valve oil pressure switch
1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON. Between BRC5B (8) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
HD465-7, HD605-7
20-1065
(10)
TROUBLESHOOTING
[DWNBK4]
20-1066
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNBKA]
[DWNBKA] SHUT-OFF SOLENOID VALVE: DISCONNECTION (KA)

Action code E01 Failure code Controller code DWNBKA BK Trouble Shut-off solenoid valve: Disconnection (KA)
Contents of trouble When the output to the shut-off solenoid valve circuit is turned ON, any current does not flow.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector ASR2. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR2 (female) (1) (2) Between ASR2 (1), (2) chassis ground Resistance 10 30 z Resistance Min. 1 Mz
Defective shut-off solenoid valve
Possible causes and standard value in normal state Disconnection in wiring 2 harness (Disconnection or defective contact)
1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter. Wiring harness between BRC2 (female) (2) Resistance Max. 1 z ASR2 (female) (1) Wiring harness between BRC2 (female) (13) Resistance Max. 1 z ASR2 (female) (2)
1) Turn starting switch OFF. 2) Disconnect connector BRC2. 3 Defective retarder controller 3) Connect T-adapter. Between BRC2 (female) (2) (13) Resistance 10 30 z
HD465-7, HD605-7
20-1067
(10)
TROUBLESHOOTING
[DWNBKB]
[DWNBKB] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT (KB)

Action code E01 Failure code Controller code DWNBKB BK Trouble Shut-off solenoid valve: Short circuit (KB)
Contents of trouble When the output to the shut-off solenoid valve circuit is turned ON, too much current flows.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector ASR2. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR2 (female) (1) (2) Between ASR2 (1), (2) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter. Resistance 10 30 z Resistance Min. 1 Mz
Possible causes and standard value in normal state 2 Ground fault or short circuit in wiring harness
Wiring harness between BRC2 (female) (2) ASR2 (female) (1) Between wiring harness between BRC2 (female) (2) ASR2 (female) (1) and between BRC2 (female) (13) ASR2 (female) (2)
Resistance between BRC2 (female) (2), ASR2 (female) (1) chassis ground Resistance between BRC2 (female) (2), ASR2 (female) (1) BRC2 (female) (13), ASR2 (female) (2)
Max. 1 z
Max. 1 z
20-1068
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNBKY]
[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Action code E01 Failure code Controller code DWNBKY BK Trouble Shut-off solenoid valve: Short circuit with power source (Hot short) (KY)
Contents of trouble When the output to the shut-off solenoid valve circuit is turned OFF, a current flows.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector ASR2. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR2 (female) (1) (2) Between ASR2 (1), (2) chassis ground Resistance 10 30 z Resistance Min. 1 Mz
1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter. 4) Connect connector 5) Turn starting switch ON. Wiring harness between BRC2 (female) (2) ASR2 (female) (1) Voltage between BRC2 (female) (2), ASR2 (female) (1) chassis ground Max. 1 V
HD465-7, HD605-7
20-1069
(10)
TROUBLESHOOTING
[DWNBMA]
[DWNBMA] SHUT-OFF SOLENOID VALVE: MALFUNCTION (MA)

Action code E01
Contents of trouble
Failure code Controller code DWNBMA BK
Trouble Shut-off solenoid valve: Malfunction (MA)
The shut-off solenoid valve does not operate (does not move) or the pressure switch system is defective.
Related information
Cause Defective shut-off solenoid 1 valve
Standard value in normal state/Remarks on troubleshooting Check the shut-off solenoid valve and repair or replace it, if it has abnormality (mechanical failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Connect T-adapter. Wiring harness between Resistance between BRC5B BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) (female) (1) (1) chassis ground Max. 1 z
Defective shut-off solenoid valve oil pressure switch
Possible causes and standard value in normal state 3 Disconnection in wiring harness
1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4) Connect connector. 4 Defective retarder controller 5) Turn starting switch ON. Between BRC5B (8) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
20-1070
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX17K4]
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): UNCONTROLLABLE (K4)
Action code E01 Failure code Controller code DX17K4 BK Trouble ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4)
The ASR proportional solenoid pressure reducing valve (Right) does not return (does not move) or the Contents of trouble pressure switch system is defective. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).
Cause
Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve 1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical valve (Right) failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR5. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Right) oil pressure 5) Turn starting switch ON. switch Between ASR5 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR5. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (7) ASR5 (female) (7), ASR5 (female) (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR5. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (7) ASR5 (female) (7), ASR5 (female) (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON. Between BRC5B (7) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V Max. 1 V Max. 1 z
HD465-7, HD605-7
20-1071
(10)
TROUBLESHOOTING
[DX17K4]
20-1072
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DX17KA]
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): DISCONNECTION (KA)
Action code E01 Failure code Controller code DX17KA BK Trouble ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA)
When the output to the ASR proportional solenoid pressure reducing valve (Right) circuit is turned ON, Contents of trouble any current does not flow. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) (2) Between ASR3 (1), (2) chassis ground Possible causes and standard value in normal state 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR3. 3) Connect T-adapter.
Resistance 10 30 z Resistance Min. 1 Mz
Disconnection in wiring harness 2 Wiring harness between BRC2 (female) (9) Resistance Max. 1 z (Disconnection or defective ASR3 (female) (1) contact) Wiring harness between BRC2 (female) (19) Resistance Max. 1 z ASR3 (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC2. 3 Defective retarder controller 3) Connect T-adapter. Between BRC2 (female) (9) (19) Resistance 10 30 z
HD465-7, HD605-7
20-1073
(10)
TROUBLESHOOTING
[DX17KB]
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): SHORT CIRCUIT (KB)
Action code E01 Failure code Controller code DX17KB BK Trouble ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any Contents of trouble current does not flow. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) (2) Between ASR3 (1), (2) chassis ground Possible causes and standard value in normal state 2 Ground fault or short circuit in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR3. 3) Connect T-adapter. Wiring harness between BRC2 (female) (9) ASR3 (female) (1)
Resistance between BRC2 (female) (9), ASR3 (female) Min. 1 Mz (1) chassis ground Min. 1 Mz
Wiring harness between BRC2 (female) (9) ASR3 (female) (1) and between BRC2 (female) (19) ASR3 (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC2. 3 Defective retarder controller 3) Connect T-adapter. Between BRC2 (female) (9) (19)
Resistance 10 30 z
20-1074
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX17KY]
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Action code E01 Failure code Controller code DX17KY BK Trouble ASR proportional solenoid pressure reducing valve (Right): Short circuit with power source (Hot short) (KY)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a curContents of trouble rent flows. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) (2) Between ASR3 (1), (2) chassis ground Possible causes and standard value in normal state 2 Hot short in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR3. 3) Insert connect T-adapter. 4) Connect connector 5) Turn starting switch ON. Wiring harness between BRC2 (female) (9) ASR3 (female) (1)
Voltage between BRC2 (female) (9), ASR3 (female) (1) chassis ground
Max. 1 V
Min. 1 Mz
Resistance 10 30 z
HD465-7, HD605-7
20-1075
(10)
TROUBLESHOOTING
[DX17MA]
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): MALFUNCTION (MA)
Action code E01 Failure code Controller code DX17MA BK Trouble ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)
The ASR proportional solenoid pressure reducing valve (Right) does not operate (does not move) or Contents of trouble the pressure switch system is defective. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).
Cause
Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve 1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical valve (Right) failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR5. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Right) oil pressure 5) Turn starting switch ON. switch Between ASR5 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR5. 3) Connect T-adapter. Wiring harness between Resistance between BRC5B BRC5B (female) (7) ASR5 (female) (7), ASR5 (female) (female) (1) (1) chassis ground Max. 1 z
Disconnection in wiring harness
1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5B (7) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
20-1076
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX18K4]
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): UNCONTROLLABLE (K4)
Action code E01 Failure code Controller code DX18K4 BK Trouble ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4)
The ASR proportional solenoid pressure reducing valve (Left) does not return (does not move) or the Contents of trouble pressure switch system is defective. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).
Cause
Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve (Left) 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve (Left) 1) Turn starting switch OFF. 2) Disconnect connector ASR6. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Left) oil pressure 5) Turn starting switch ON. switch Between ASR6 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR6. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (6) ASR6 (female) (6), ASR6 (female) (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR6. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Voltage between BRC5B BRC5B (female) (6) ASR6 (female) (6), ASR6 (female) (female) (1) (1) chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON. Between BRC5B (6) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V Max. 1 V Max. 1 z
HD465-7, HD605-7
20-1077
(10)
TROUBLESHOOTING
[DX18K4]
20-1078
(5)
HD465-7, HD605-7
TROUBLESHOOTING
[DX18KA]
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): DISCONNECTION (KA)
Action code E01 Failure code Controller code DX18KA BK Trouble ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA)
When the output to the ASR proportional solenoid pressure reducing valve (Left) circuit is turned ON, Contents of trouble any current does not flow. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) (2) Between ASR4 (1), (2) chassis ground Possible causes and standard value in normal state Disconnection in wiring 2 harness (Disconnection or defective contact) 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR4. 3) Connect T-adapter.
Wiring harness between BRC2 (female) (8) Resistance Max. 1 z ASR4 (female) (1) Wiring harness between BRC2 (female) (18) Resistance Max. 1 z ASR4 (female) (2)
HD465-7, HD605-7
20-1079
(10)
TROUBLESHOOTING
[DX18KB]
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): SHORT CIRCUIT (KB)
Action code E01 Failure code Controller code DX18KB BK Trouble ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any Contents of trouble current does not flow. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) (2) Between ASR4 (1), (2) chassis ground Possible causes and standard value in normal state 2 Ground fault or short circuit in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR4. 3) Connect T-adapter. Wiring harness between BRC2 (female) (8) ASR4 (female) (1)
Resistance between BRC2 (female) (8), ASR4 (female) Min. 1 Mz (1) chassis ground Min. 1 Mz
Resistance 10 30 z
20-1080
(10)
HD465-7, HD605-7
TROUBLESHOOTING
[DX18KY]
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Action code E01 Failure code Controller code DX18KY BK Trouble ASR proportional solenoid pressure reducing valve (Left): Short circuit with power source (Hot short) (KY)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a curContents of trouble rent flows. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information
Cause
1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) (2) Between ASR4 (1), (2) chassis ground Possible causes and standard value in normal state 2 Hot short in wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR4. 3) Insert connect T-adapter. 4) Connect connector 5) Turn starting switch ON. Wiring harness between BRC2 (female) (8) ASR4 (female) (1)
Voltage between BRC2 (female) (8), ASR4 (female) (1) chassis ground
Max. 1 V
Min. 1 Mz
Resistance 10 30 z
HD465-7, HD605-7
20-1081
(10)
TROUBLESHOOTING
[DX18MA]
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): MALFUNCTION (MA)
Action code E01 Failure code Controller code DX18MA BK Trouble ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA)
The ASR proportional solenoid pressure reducing valve (Left) does not operate (does not move) or the Contents of trouble pressure switch system is defective. Action of controller Resets the ASR control. The machine is not affected badly. Problem that appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).
Cause
Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve (Left) 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve (Left) 1) Turn starting switch OFF. 2) Disconnect connector ASR6. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Left) oil pressure 5) Turn starting switch ON. switch Between ASR6 (female) (1) Oil pressure ON Resistance Max. 1 z (2) Oil pressure OFF Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR6. 3) Connect T-adapter. Wiring harness between Resistance between BRC5B BRC5B (female) (6) ASR6 (female) (6), ASR6 (female) (female) (1) (1) chassis ground Max. 1 z
Disconnection in wiring harness
1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5B (6) BRC2 Oil pressure ON (21) Oil pressure OFF Voltage Voltage Max. 1 V 20 30 V
20-1082
(10)
HD465-7, HD605-7
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
H-1 H-2 H-3 H-4 H-5
Machine does not start ....................................................................................................................20-1102 Machine does not travel smoothly (machine jerks) .........................................................................20-1104 Lock-up clutch cannot be disengaged (engine stalls) .....................................................................20-1104 Excessive shock when starting or shifting.......................................................................................20-1105 Transmission does not shift up........................................................................................................20-1105 a. Does not shift up ........................................................................................................................20-1105 b. Does not shift up ........................................................................................................................20-1105
H-6
Machine lacks power or speed when traveling................................................................................20-1106 a. Abnormality at all speed ranges.................................................................................................20-1106 b. Torque converter lock-up does not engage................................................................................20-1107 c. Abnormality at specific speed ranges ........................................................................................20-1108
H-7 H-8 H-9
Time lag is excessive when starting or shifting gear .......................................................................20-1110 Torque converter oil temperature is high .........................................................................................20-1112 Torque converter oil pressure is low................................................................................................20-1113
H-10 Front brake is ineffective, or effective only on one side ..................................................................20-1114 H-11 Rear brake is ineffective, or effective only on one side ...................................................................20-1115 H-12 Steering wheel is heavy ..................................................................................................................20-1116 H-13 Steering wheel does not work .........................................................................................................20-1117 H-14 Steering wheel vibrates ...................................................................................................................20-1117 H-15 Hoist cylinder lacks lifting force (lifting speed) ...............................................................................20-1118 H-16 Hoist cylinder does not work ...........................................................................................................20-1119 H-17 Excessive hydraulic drift of dump body ...........................................................................................20-1120
HD465-7, HD605-7
20-1101
(2)
TROUBLESHOOTING
H-1
H-1 Machine does not start

Ask the operator the following questions Did the problem suddenly happen? Yes = Internal seizure, damage When this happened, was there any abnormal noise? Yes = Broken part Checks before troubleshooting Is the oil level in the transmission case correct? Is the torque converter, transmission input shaft broken? (Check with the transmission input shaft speed sensor.) Is the drive shaft broken? Is there any dragging of the brakes? Is any failure code related power trains displayed?
Drop in set pressure of main relief valve (torque converter valve)
Defective transmission clutch seal ring, groove
Defective speed clutch (defective oil tightness)
Defective shaft seal ring in speed clutch circuit
Defective actuation of ECMV solenoid valve m
Causes
Pump does not drive (defective PTO)
Air sucked in at suction side of pump
Defective operation of ECMV valve
Damage inside torque converter
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 Set pressure of transmission is low Abnormal noise comes from between pump and filter Machine does not start in any speed range (Item 1 normal) Machine starts normally in certain speed range Machine does not start when torque converter oil temperature rises Low at every speed range Becomes lower at certain speed range Indicator is unstable and fluctuates excessively When pressure pickup plug is removed and engine is cranked, no oil comes out Modulation pressure is abnormal Hydraulic pressure at pump outlet port is low C
20-1102
(10)
HD465-7, HD605-7
Defective speed sensor function n
Damage inside transmission
Seized transmission clutch
Clogged strainer
Defective pump
TROUBLESHOOTING
H-1
Clutch combination table

Clutch No. Speed range R N F1 F2 F3 F4 F5 F6 F7
4th
3rd
2nd
1st
(Rotat- (Rotating) ing)
HD465-7, HD605-7
20-1103
(2)
TROUBLESHOOTING
H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)

There is hunting. Look-up lamp flashes. Checks before troubleshooting Is the oil level in the transmission case correct? Is any failure code related power trains displayed?
Causes Drop in main relief pressure A. See H-6 Worn clutch seal ring Remedy
H-3 Lock-up clutch cannot be disengaged (engine stalls)

Checks before troubleshooting Is the oil level in the transmission case correct? Is any failure code related power trains displayed?
Defective actuation of lock-up ECMV solenoid valve
Defective actuation of lock-up ECMV valve b C
Causes
a Remedy . No. Problems 1 2 3 4 Lock-up pressure does not become "0" Lock-up clutch is not disengaged even when lock-up pressure is "0" Operation of lock-up ECMV valve is normal Operation of lock-up ECMV solenoid valve is normal
20-1104
(10)
Seized lock-up clutch c
HD465-7, HD605-7
TROUBLESHOOTING
H-4, H-5
H-4 Excessive shock when starting or shifting

Judgement standard There is some shock, but it is difficult to judge if the shock is excessive or not, so judge that it is excessive in the following cases. It is clear that the shock has suddenly become excessive. The shock is excessive compared with other machines of the same class. Cause Defective operation because of dirt caught in the ECMV pressure control valve spool and pressure detector valve spool, or defective operation of the ECMV proportional solenoid.
H-5 Transmission does not shift up

a. Does not shift up
a Shifts up on downhill slopes.
Causes Slipping or damage of torque converter lock-up clutch Remedy
a The above is the most probable cause, but for details, see "Torque converter lock-up does not engage".
b. Does not shift up

Causes Defective operation of ECMV for clutch which does not shift up Defective piston seal ring, defective groove for clutch which does not shift up Drop in main relief pressure A C C Remedy

4th
3rd
2nd
1st
HD465-7, HD605-7
20-1105
(10)
TROUBLESHOOTING
H-6
H-6 Machine lacks power or speed when traveling

a. Abnormality at all speed ranges
Checks before troubleshooting Is the oil level in the transmission case correct? Is there any external oil leakage from the piping or valve joints? Is there any dragging of the parking brake, service brake, or retarder? Is any failure code related power trains displayed? Checking for abnormalities Engine high idle speed Torque converter stall speed Machine travel speed Transmission clutch pressure Torque converter lock-up pressure Main relief pressure
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
Defective operation of torque converter relief valve, deteriorated spring
Drop in set pressure of main relief valve (torque converter valve)
Cooler, piping beyond torque converter outlet port damaged
Damage inside torque converter (turbine rivet broken) j
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 Set pressure of transmission is low Abnormal noise comes from between pump and filter Torque converter stall speed is high Torque converter stall speed is low Low at every speed range (Item 2 abnormal) Indicator is unstable and fluctuates excessively Low after entering torque converter lock-up Hydraulic pressure at torque converter inlet port is low (Items 4 6 normal) Hydraulic pressure at torque converter outlet port is low (Item 7 normal) Pieces of iron and aluminium stuck to strainer and drain plug of transmission case Hydraulic pressure at pump outlet port is low When oil temperature rises, oil pressure drops C
e A
h A
See TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
20-1106
(10)
HD465-7, HD605-7
See b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
Torque converter lock-up does not engage k
Causes
Defective torque converter freewheel
Drop in performance of engine
Crogged strainer
Defective pump
TROUBLESHOOTING
H-6
b. Torque converter lock-up does not engage

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 Is any failure code related power trains displayed? Checks before troubleshooting Is the oil level in the transmission case correct? Is there any external oil leakage ? Is electricity flowing to the lock-up solenoid? (Use a checker) Checking for abnormalities Main relief pressure Lock-up oil pressure Main travel speed
Defective operation of lock-up ECMV solenoid valve spool
Defective operation of lock-up ECMV valve spool
Drop in set pressure of main relief valve
Causes
Worn lock-up clutch piston seal ring
Defective lock-up ECMV solenoid
a Remedy No. Problems 1 2 3 4 5 6 7 8 Main relief pressure is low With Item 1 normal, lock-up pressure is low or "0" Solenoid is normal in Item 2 (proper continuity, no short circuit) Solenoid is defective in Item 2 (no continuity, there is short circuit) With Items 1 4 normal, lock-up pressure is low Oil pressure is normal in Item 5 Lock-up pressure is low and main pressure is also low Lock-up takes time to engage
Cracked lock-up clutch case g
Worn lock-up clutch disc
HD465-7, HD605-7
20-1107
(10)
TROUBLESHOOTING
H-6
c. Abnormality at specific speed ranges

Checks before troubleshooting Is the oil level in the transmission case correct? Is there any dragging of the parking brake, service brake, or retarder? Is any failure code related power trains displayed? Checking for abnormalities Machine travel speed

4th
3rd
2nd
1st
Remedy No. Problems 1 (1) F1 is normal, but F2 is defective (2) Returns to normal when replaced with any ECMV except 2nd. 2 (1) F2 is normal, but F1 is defective or only F1 is defective (2) Returns to normal when replaced with any ECMV except 1st. 3 (1) F1 and F2 are normal, but F3 is defective (2) Returns to normal when replaced with any ECMV except H. 4 (1) F1, F2 and F3 are normal, but F4 is defective (2) Returns to normal when replaced with any ECMV except 3rd. 5 (1) F1 F5 are normal, but F6 is defective (2) Returns to normal when replaced with any ECMV except 4th. 6 (1) F3, F5, and F7 are normal, but others are defective (2) Returns to normal when replaced with any ECMV except L. 7 (1) Only R is defective (2) Returns to normal when replaced with any ECMV except R.
a Remove all the mud and dirt from around the ECMV, and clean it before replacing. a After replacing, tighten the ECMV mounting bolts to the specified tightening torque. ECMV mounting bolt : 8.0 10.0 Nm {0.8 1.0 kgm}
20-1108
(7)
HD465-7, HD605-7
Causes a b c 4th clutch disc worn or seized, seal ring worn 3rd clutch disc worn or seized, seal ring worn 2nd clutch disc worn or seized, seal ring worn 1st clutch disc worn or seized, seal ring worn R clutch disc worn or seized, seal ring worn Defective operation of H clutch ECMV Defective operation of L clutch ECMV Defective operation of 4th clutch ECMV Defective operation of 3rd clutch ECMV Defective operation of 2nd clutch ECMV Defective operation of 1st clutch ECMV Defective operation of R clutch ECMV L clutch disc worn or seized, seal ring worn H clutch disc worn or seized, seal ring worn
HD465-7, HD605-7
d e f g h i j k l m n
TROUBLESHOOTING
20-1109
(7)
H-6
TROUBLESHOOTING
H-7
H-7 Time lag is excessive when starting or shifting gear

Checks before troubleshooting Is the oil level in the transmission case correct? Is there any external oil leakage from the piping or valve joints? Is operation of control valve normal? Is any failure code related power trains displayed? Checking for abnormalities See the STANDARD VALUE TABLE to check if the time lag is actually excessive. Clutch combination table
4th
3rd
2nd
1st
Remedy No. Problems 1 2 3 4 5 6 7 8 9 Abnormal noise comes from pump There is time lag when transmission is placed in any speed range F1 is normal, but there is time lag when shifting to F2 F2 is normal, but there is time lag when shifting to F1 F1 and F2 are normal, but there is time lag when shifting to F3 F1, F2, and F3 are normal, but there is time lag when shifting to F4 F1 - F5 are normal, but there is time lag when shifting to F6 F3, F5, and F7 are normal, but there is time lag when in other speed ranges There is time lag in R
10 Transmission modulating pressure is low when placed in any speed range 11 Torque converter oil temperature goes above operating range
20-1110
(2)
HD465-7, HD605-7
Causes a b c Defective pump Defective oil tightness in rotating clutch 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 R clutch disc worn or defective seal ring, worn groove Defective operation of H clutch ECMV Defective operation of L clutch ECMV Defective operation of 4th clutch ECMV Defective operation of 3rd clutch ECMV Defective operation of 2nd clutch ECMV Defective operation of 1st clutch ECMV Defective operation of R clutch ECMV Air sucked in at suction side of pump C Clogged strainer
HD465-7, HD605-7
d e f g h i j k l m n o p q r s t
TROUBLESHOOTING
20-1111
(7)
H-7
TROUBLESHOOTING
H-8
H-8 Torque converter oil temperature is high

Ask the operator the following questions 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) Checks before troubleshooting Is oil level in transmission case correct? Is any failure code related power trains displayed? Checking for abnormalities Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high. a If oil temperature is normal but oil temperature gauge on machine goes above operating range. odefective oil temperature gauge
Tank-pump a Remedy No. Problems 1 2 3 4 5 6 Pump makes abnormal noise when oil temperature is low High idle and low idle speeds are low Torque converter outlet port oil pressure is low Torque converter inlet port oil pressure is low Transmission modulating pressure is low Excessive leakage inside torque converter C b c d
Torque converter
If troubleshooting shows that all other items are normal, this is the cause.
20-1112
(10)
Oil leakage inside torque converter (defective seal ring, loose bolt, crack in pump, turbine) f
Defective operation of torque converter relief valve
Causes Clogged strainer
Defective pump
Clogged filter
HD465-7, HD605-7
TROUBLESHOOTING
H-9
H-9 Torque converter oil pressure is low

Checks before troubleshooting Is the oil level in the transmission case correct? Is there any external oil leakage from the piping or valve joints? Is any failure code related power trains displayed? Checking for abnormalities 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 c
a Remedy No. Problems 1 2 3 4 5 Abnormal noise comes from pump Oil pressure is low between pump and relief valve Torque converter inlet port pressure is low Transmission and lock-up pressures are normal, but torque converter inlet pressure is low When set pressure of torque converter relief valve is adjusted, inlet pressure becomes high C
Excessive leakage inside torque converter d
Causes
Defective hydraulic pump
HD465-7, HD605-7
20-1113
(2)
TROUBLESHOOTING
H-10
H-10 Front brake is ineffective, or effective only on one side

Checks before troubleshooting Is the oil level in the transmission case correct? Is the brake pedal play correct? Is there any leakage of oil from the brake piping or deformation of the piping? Is the tire inflation and tread condition normal? Is any failure code related to the brakes displayed? Is the front brake cut-off switch turned on?
Drop in front brake accumulator gas pressure (gas leakage, defective piston seal
Air sucked in at suction side of brake operating pump
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 h
Defective brake operating pump
Defective brake valve (front)
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 12 13 Brake has no effect only when brake pedal is depressed When brake pedal is depressed, it is light When brake pedal is depressed, it is heavy Extremely large operating effort is needed to obtain specified braking effect Hydraulic and steering do not work Abnormal noise is heard from around PTO Abnormal noise is heard from around transmission oil pan or PPC pump Accumulator charge pressure is low Brake immediately loses power after engine is stopped There is time lag before brake starts to take effect Brake oil pressure is low When air is bled from brake system, air comes out When front brake cut-off switch is turned ON (When its lower part is pressed), front brake is not released
20-1114
(10)
Air in brake circuit i
HD465-7, HD605-7
TROUBLESHOOTING
H-11
H-11 Rear brake is ineffective, or effective only on one side

Checks before troubleshooting Is the oil level in the transmission case correct? Is the brake pedal play correct? Is there any leakage of oil from the brake piping or deformation of the piping? Is the tire inflation and tread condition normal? Is any failure code related to the brakes displayed?
Defective brake operating pump drive system (PTO)
Drop in rear brake accumulator gas pressure (gas leakage, defective piston seal)
Defective retarder solenoid valve (Proportional reducing valve)
Air sucked in at suction side of brake operating pump
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 n
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Brake has no effect only when brake pedal is depressed When brake pedal is depressed, it is light When brake pedal is depressed, it is heavy Even when retarder lever is pulled, retarder has no effect Extremely large operating effort is needed to obtain specified braking effect When brakes are applied, abnormal noise is heard from brake portion of axle Hydraulic and steering do not work Abnormal noise is heard from around PTO Abnormal noise is heard from around transmission oil pan or PPC pump When oil is drained from inside axle case, large amounts of metal particles are found Accumulator charge pressure is low Brake immediately loses power after engine is stopped There is time lag before brake starts to take effect Brake oil pressure is low Brake disc wear amount is high When air is bled from brake system, air comes out
HD465-7, HD605-7
20-1115
(10)
Improper axle oil O
TROUBLESHOOTING
H-12
H-12 Steering wheel is heavy

Checks before troubleshooting 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? Checking for abnormalities 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
Air sucked in at suction end
Defective opening of check valve
Defective steering cylinder i
Defective steering pump
Demand valve
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 Circuit pressure is too high at engine low idle or pressure rises to relief pressure Relief pressure in steering circuit is too low Hoist force is also low Item 3 is abnormal and noise of oil blowing is heard from relief valve Relief pressure is low at end of cylinder stroke (Items 1 4 normal) Abnormal noise comes from between pump and filter When steering wheel is turned to right (left), oil flows out continuously when hose on opposite side is removed Condition is normal at engine low idle Pump discharge amount is too low Item 3 is normal but speed is slow Excessive play in steering wheel
c C
f A
20-1116
(10)
HD465-7, HD605-7
Defective steering valve j
Crushed suction tube
Defective hoist pump
Clogged strainer
TROUBLESHOOTING
H-13, H-14
H-13 Steering wheel does not work

Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is there any external oil leakage between pump and steering valve? Is the steering wheel play correct? Is any failure code related steerings displayed? Checking for abnormalities Relief pressure
Causes
Air sucked in at suction side
Defective steering cylinder j
Demand valve
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 Hoist cylinder also does not work When pressure pickup port plug is removed and engine is cranked, no oil comes out Circuit pressure is too high at engine low idle, or pressure rises to relief pressure (Item 2 normal) Hoist is normal Relief pressure is low at end of cylinder stroke (Item 4 normal) Item 5 is abnormal and noise of oil blowing is heard from relief valve Abnormal noise comes from between pump and filter Steering wheel works when engine is at low idle When steering wheel is turned to right (left) and hose on opposite side is removed, rod does not move but oil flows out Pump discharge amount is too low Excessive play in steering wheel
d C
g A
H-14 Steering wheel vibrates

Checks before troubleshooting Is any failure code related steerings displayed?
Causes Air in hydraulic oil Leakage of air inside steering cylinder Remedy A
Defective steering valve k
Defective hoist pump
Clogged strainer
HD465-7, HD605-7
20-1117
(10)
TROUBLESHOOTING
H-15
H-15 Hoist cylinder lacks lifting force (lifting speed)

Checks before troubleshooting Is the oil level in the hydraulic tank correct? 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 displayed? Is there any external oil leakage from between pump and cylinder?
Drop in safety valve set pressure or defective sealing
Checking for abnormalities Relief pressure Body lifting speed
Demand valve
Hoist valve i A j k
a Remedy No. 1 2 3 4 5 6 7 8 9 10 11 12 13
b C
f A C
Problems Steering wheel is also heavy Steering wheel is normal Item 1 is defective and hoist circuit relief pressure is low Item 3 is abnormal and noise of oil blowing is heard from relief valve Hoist circuit pressure is too high at engine high idle (Items 1 4 are normal) Only hoist circuit relief pressure is low Item 6 is abnormal and noise of oil blowing is heard from relief valve Dump body rises irregularly Pump discharge amount is low Measured dump EPC valve oil pressure is low Excessive hydraulic drift of hoist cylinde Items 1 10 are normal but dump body lifting speed is slow Abnormal noise comes from between pump and filter
20-1118
(10)
HD465-7, HD605-7
Drop in dump EPC circuit oil pressure or defective operation of EPC valve n A
Drop in performance of hydraulic pump
Drop in performance of steering pump
Causes
Defective hoist cylinder
Defective dump lever
Clogged strainer
TROUBLESHOOTING
H-16
H-16 Hoist cylinder does not work

Ask the operator the following questions Did the problem suddenly happen? Yes = Seizure, damage to equipment Had drop in lifting speed or other symptoms appeared before? Yes = Worn parts, deteriorated spring, etc. Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the input signal value of the dump lever in the normal range? Is any failure code related dump bodys displayed?
Causes
Crushed pump suction tube
Defective hydraulic pump
Checking for abnormalities Relief pressure
Demand valve
Hoist valve i A j A k
a Remedy No. Problems 1 2 3 4 5 6 7 8 9 10 11 12 When pressure pickup port plug is removed and engine is cranked, no oil comes out Steering also does not work Steering is normal, only hoist does not work In Item 2, hoist circuit relief pressure is low Item 4 is abnormal and noise of oil blowing is heard from relief valve Only hoist circuit relief pressure is low at engine high idle Item 4 is abnormal and noise of oil blowing is heard from relief valve Hoist circuit pressure is too high at engine low idle or pressure rises to relief pressure (Items 1 - 5 normal) Works when engine is at low idle Pump discharge amount is low When hoist lever is operated to RAISE, and hose on opposite side is removed, cylinder does not move, but oil comes out Measured dump EPC valve oil pressure is low
c C
f A
HD465-7, HD605-7
20-1119
(10)
Drop in dump EPC circuit oil pressure or defective operation of EPC valve n
Drop in safety valve set pressure or defective sealing
Defective hoist cylinder
Defective dump lever
Clogged strainer
TROUBLESHOOTING
H-17
H-17 Excessive hydraulic drift of dump body

Checks before troubleshooting Is any failure code related dump bodys displayed? Checking for abnormalities Hydraulic drift of cylinder
Causes
Defective hoist cylinder piston ring a
Remedy No. Problems 1 2 When engine is stopped with Oil continues to flow out body fully raised and head pipOil does not continue to flow out ing is removed
20-1120
(10)
Defective sealing of valve spool b
HD465-7, HD605-7
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

Points to remember when troubleshooting.................................................................................................20-1152 Method of using troubleshooting charts .....................................................................................................20-1153 S- 1 Starting performance is poor (starting always takes time) .............................................................20-1156 S- 2 Engine does not start ....................................................................................................................20-1159 a) Engine does not turn ................................................................................................................20-1159 b) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............................20-1160 c) Exhaust smoke comes out but engine does not start (fuel is being injected) ..........................20-1162 S- 3 Engine does not pick up smoothly (follow-up is poor) ...................................................................20-1164 S- 4 Engine stops during operations .....................................................................................................20-1166 S- 5 Engine does not rotate smoothly (hunting) ....................................................................................20-1168 S- 6 Engine lacks output (or lacks power).............................................................................................20-1170 S- 7 Exhaust smoke is black (incomplete combustion) ........................................................................20-1172 S- 8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................20-1175 S- 9 Oil becomes contaminated quickly ...............................................................................................20-1176 S-10 Fuel consumption is excessive ......................................................................................................20-1177 S-11 Oil is in coolant, or water spurts back, or water level goes down .................................................20-1178 S-12 Oil pressure warning lamp lights up (drop in oil pressure).............................................................20-1179 S-13 Oil level rises .................................................................................................................................20-1180 S-14 Coolant temperature becomes too high (overheating) .................................................................20-1181 S-15 Abnormal noise is made ................................................................................................................20-1182 S-16 Vibration is excessive ....................................................................................................................20-1183
HD465-7, HD605-7
20-1151
(10)
TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the coolant temperature to go down before removing the radiator cap. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. When removing a plug or cap from a location which is under pressure from oil, coolant, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: Parts that have no connection with the failure or other unnecessary parts will be disassembled It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-1152
(10)
HD465-7, HD605-7
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in (B) are items that can be obtained from the user, depending on the user's level.
[Check items]
The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.
HD465-7, HD605-7
20-1153
(10)
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black Insufficient intake of air Defective condition of fuel injection Excessive injection of fuel Defective HPI sensor Defective HPI actuator Normal output is not applied a See Troubleshooting S-6
20-1154
(10)
HD465-7, HD605-7
TROUBLESHOOTING
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
Three symptoms
Step 2 Add up the total of and marks where the horizontal limes for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Defective contact of valve, valve seat: (3) Leakage of air between turbocharger and head: (4) Worn piston ring, cylinder liner: (5) Defective timing rail pressure sensor:
Step 3 The calculation in Step 2 shows that the closest relationship is with [Worn piston ring, cylinder liner]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
HD465-7, HD605-7
20-1155
(10)
TROUBLESHOOTING
S-1
S-1
Starting performance is poor (starting always takes time)

Causes
Defective preheating circuit (when starting in low temperatures)
Defective contact of valve, valve seat
General causes why starting performance is poor Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel Defective HPI sensor Defective HPI actuator
Clogged air cleaner element
Clogged timing rail actuator screen
Loose piping, fuel filter, entry of air
Defective or deteriorated battery
Worn piston ring, cylinder liner
Confirm recent repair history Degree of use of machine Engine starts easily when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Charge caution lamp lights up When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged Starting motor cranks engine slowly When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting motor, Fuel pump outlet port coupler is pushed, air comes out together with fuel Check items When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Difficult to stop engine Inspect air cleaner element directly When compression pressure is measured, it is found to be low Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
Operated for long period
Starting performance became worse gradually Questions
When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low Inspect fuel pump directly Troubleshooting Inspect fuel shut-off valve directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect injector directly When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is turned to HEAT, heater mount does not become warm Is voltage 26 - 30V between alternator terminal B and terminal E with engine at low idle? Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Clean Clean Clean Clean Yes No
Remedy
20-1156
(10)
HD465-7, HD605-7
Defective alternator regulator
Defective injector check ball
Clogged fuel filter, strainer
Cut, worn injector O-ring
Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
TROUBLESHOOTING
S-1
Causes
Defective intake manifold temperature sensor
Defective atmospheric pressure sensor
Defective coolant temperature sensor
Defective fuel pump pressure sensor
Defective timing rail pressure sensor
Defective fuel rail pressure sensor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Defective fuel pump actuator (*1)
Defective timing rail actuator (*1)
Defective boost pressure sensor
(*1) If the following failure codes are displayed, carry out the troubleshooting in "ENG mode". (If any of the following failure codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C514LK]:Abnormality in fuel rail actuator [C112LK]:Abnormality in timing rail actuator [C318LK]:Abnormality in fuel pump actuator
Defective fuel rail actuator (*1)
HD465-7, HD605-7
20-1157
(10)
TROUBLESHOOTING
S-2
S-2
Engine does not start
a) Engine does not turn General causes why engine does not turn Internal parts of engine seized a See Troubleshooting S-4. Defective electrical system Problem in power train (troubleshooting for machine) a See the manual for the machine.
Causes
Confirm recent repair history Questions Degree of use of machine Condition of horn when starting switch is turned ON Battery electrolyte is low Battery terminal is loose When starting switch is turned to ON, there is no clicking sound from battery relay When starting switch is turned to START, starting pinion does not move out Check items Speed of rotation is low When starting switch is turned to START, starting pinion moves out, but Makes grating noise Soon disengages again Makes rattling noise and does not turn Inspect flywheel ring gear directly Troubleshooting When specific gravity of electrolyte and voltage of battery are measured, one of them is low When terminal B and terminal C of starting switch are connected, engine starts Turn starting switch OFF, connect cord, and carry out troubleshooting at ON There is no 24V between battery relay terminal B and terminal E When terminal B and terminal C of starting motor are connected, engine starts When terminal B and terminal C of safety relay are connected, engine starts When terminal of safety switch and terminal B of starting motor are connected, engine starts Replace Replace Correct
Remedy
Operated for long period Horn does not sound Horn volume is low
(*1)
Replace
Replace
Replace
(*1) Carry out troubleshooting of machine
HD465-7, HD605-7
20-1159
(10)
Replace
Defective starting motor safety relay or safety switch
Defective battery terminal connection
Defective starting circuit wiring
Broken flywheel ring gear
Defective starting switch
Defective starting motor
Defective battery relay
TROUBLESHOOTING
S-2
b) Engine turns but no exhaust smoke comes out (fuel is not being injected) General causes why engine turns but no exhaust smoke comes out Fuel is not being supplied Supply of fuel is extremely small Improper selection of fuel (particularly in winter) Defective HPI sensor Defective HPI actuator
Causes
Confirm recent repair history Questions Degree of use of machine Operated for long period Exhaust smoke suddenly stopped coming out (when starting again) Starting performance became worse gradually Starts when engine is warm Replacement of filters has not been carried out according to Operation Manual When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is drained, fuel does not come out Check items There is leakage from fuel piping Wiring of fuel shut-off valve is loose Cylinder block ground wiring is loose When engine is cranked with starting motor, and Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel
When negative pressure at inlet port of fuel pump is measured, it is found to be high Inspect fuel filter, strainer directly Troubleshooting Inspect fuel pump drive shaft directly Inspect fuel shut-off valve directly When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector pins Inspect timing rail actuator screen directly Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Replace Replace Replace Replace
Remedy
20-1160
(10)
HD465-7, HD605-7
Replace
Correct
Clean
Clean
Add
Defective fuel shut-off valve wiring
Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
TROUBLESHOOTING
S-2
Causes
Defective intake manifold temperature sensor
Defective coolant temperature sensor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7
20-1161
(10)
TROUBLESHOOTING
S-2
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil Defective HPI sensor Defective HPI actuator
Causes Defective dynamic valve system (valve, rocker arm, etc.)
Confirm recent repair history Degree of use of machine Questions Suddenly failed to start Starting performance became worse gradually Starts when engine is warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained Check items When fuel filter is drained, no fuel comes out There is leakage from fuel piping Starting motor cranks engine slowly When engine is cranked, abnormal noise is generated around cylinder head When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Inspect air cleaner element directly Inspect dynamic valve system directly When compression pressure is measured, it is found to be low When negative pressure at inlet port of fuel pump is measured, it is found to be high Troubleshooting When fuel filter, strainer directly Inspect fuel pump directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is at HEAT, heater mount does not become warm Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator directly Replace Replace Replace Replace Replace Replace
Remedy
20-1162
(10)
HD465-7, HD605-7
Correct
Clean
Clean
Clean
Clean
Defective preheating heater circuit
Clogged timing actuator screen
Defective fuel pump
Defective injector
Replace Defective boost pressure sensor Defective fuel rail pressure sensor Defective timing rail pressure sensor Defective fuel pump pressure sensor Causes Defective coolant temperature sensor Defective intake manifold temperature sensor Defective fuel rail actuator (*1) Defective timing rail actuator (*1) Defective fuel pump actuator (*1) Clogged fuel rail actuator
Replace
Replace
Replace
Replace
HD465-7, HD605-7 (*1) If the following failure codes are displayed, carry out the troubleshooting in "ENG mode". (If any of the following failure codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C514LK]:Abnormality in fuel rail actuator [C112LK]:Abnormality in timing rail actuator [C318LK]:Abnormality in fuel pump actuator
Replace
Replace
TROUBLESHOOTING
Replace
Replace
Replace
Replace
20-1163
(10)
S-2
TROUBLESHOOTING
S-3
S-3
Engine does not pick up smoothly (follow-up is poor)

Causes
Defective contact of valve and valve seat
Confirm recent repair history Degree of use of machine Questions Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel is drained There is leakage from fuel piping When engine is cranked with starting motor, and Check items Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel Blue under light load Black Operated for long period Engine pick-up suddenly became worse
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas
Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low Inspect valve clearance directly
Troubleshooting
When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When intake air pressure (boost pressure) is measured, it is found to be normal Inspect actuator directly (Resistance and filter for clogging) Inspect sensor directly (Output voltage and resistance) Inspect for air leakage Replace Replace Replace Replace Replace Correct Correct Correct Clean Clean Clean
Remedy
20-1164
(10)
HD465-7, HD605-7
Improper valve clearance
General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Defective condition of fuel spray Improper fuel used Abnormality in fuel control system Defective HPI sensor Defective HPI actuator Normal output is not applied (See Troubleshooting S-6)
Seized turbocharger
Defective fuel pump
Defective injector
TROUBLESHOOTING
S-3
Causes Air leakage from piping between turbocharger and cylinder head
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7
20-1165
(10)
TROUBLESHOOTING
S-4
S-4
Engine stops during operations
Broken dynamic valve system (valve, rocker arm, etc.)
Defective in power train (troubleshooting for machine) Carry out troubleshooting of machine
Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)
Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine stopped Questions Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Fuel level warning lamp lights up When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Does not turn at all Check items When it is attempted to turn by hand using barring tool Turns in opposite direction Moves amount of gear backlash
Fuel pump shaft does not turn When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston, connecting rod directly Inspect main bearing, connecting rod directly Inspect gear train directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low
When temperature of injector of each cylinder is measured, there are some cylinders that are low
Troubleshooting
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Replace Replace Replace Replace Replace Replace Replace Correct Correct Clean
20-1166
(10)
Add
Remedy
HD465-7, HD605-7
Replace
Broken, seized piston, connecting rod
General causes why engine stops during operations Seized parts inside engine There is overheating a See Troubleshooting S-14. Problem in power train (troubleshooting for machine) a See the manual for the machine. Defective HPI sensor Defective HPI actuator Low power source voltage of controller
Causes
Broken fuel pump drive shaft
Broken, seized gear train
Defective injector
TROUBLESHOOTING
S-4
Causes
Defective fuel shut-off valve Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clogged fuel inlet circuit
HD465-7, HD605-7
20-1167
(10)
TROUBLESHOOTING
S-5
S-5
Engine does not rotate smoothly (hunting)

Causes
Confirm recent repair history Degree of use of machine Questions Operated for long period Occurs at a certain speed range Condition of hunting Occurs at low idle Occurs even when speed is raised Occurs on slopes When fuel tank is inspected, it is found to be empty Rust, water are found when fuel tank is drained Leakage from fuel piping Check items When engine is cranked with starting motor, and Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine speed sometimes rises too far Engine is difficult to stop Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When flow of spill fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator screen directly Inspect timing rail actuator screen directly Replace Replace Replace Replace Replace Replace Replace Clean Clean
Remedy
Troubleshooting
20-1168
(10)
HD465-7, HD605-7
Clean
High resistance, clogged fuel return circuit
Defective actuation of timing rail actuator
Defective actuation of fuel rail actuator
General causes why engine does not rotate smoothly Air in fuel system Defective governor mechanism Defective HPI sensor Defective HPI actuator Normal output is not applied a See Troubleshooting S-6
Defective injector check ball
Defective fuel pump
Defective injector
Replace Defective atmospheric pressure sensor Defective boost pressure sensor Defective fuel rail pressure sensor Defective timing rail pressure sensor Defective fuel pump pressure sensor Defective fuel pump actuator (*1) Defective in throttle sensor Defective in speed sensor Clogged fuel rail actuator screen Clogged timing rail actuator screen
Replace
Replace
Replace
Replace
Causes
HD465-7, HD605-7 (*1) If the following failure code is displayed, carry out the troubleshooting in "ENG mode". (If it is not displayed, it is not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C318LK]: Abnormality in fuel pump actuator
Replace
TROUBLESHOOTING
Replace
Replace
Replace
20-1169
(10)
S-5
TROUBLESHOOTING
S-6
S-6
Engine lacks output (or lacks power)
a Measure the engine speed and judge if the problem is in the engine or on the machine. General causes why engine lacks output Insufficient intake of air Insufficient supply of fuel Improper fuel used (if non-specified fuel is used, output drops) There is overheating a See Troubleshooting S-14. Defective HPI sensor Defective HPI actuator Wrong pare number of controller High fuel temperature
Causes
Improper adjustment of valve clearance
Confirm recent repair history Degree of use of machine Questions Power was lost Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator lamp is red When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Operated for long period Suddenly Gradually
Color of exhaust gas Check items
Black Blue under light load
Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is irregular There is hunting from engine (rotation is irregular) High idle speed of engine is low Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low Inspect valve clearance directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low
When temperature of injector of each cylinder is measured, there are some cylinders that are low
Troubleshooting
Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Check part No. of controller calibration data Replace Replace Replace Replace Replace Replace
Remedy
20-1170
(10)
HD465-7, HD605-7
Replace
Correct
Adjust
Clean
Clean
Clean
Seized turbocharger, interference
Defective fuel pump
Defective injector
TROUBLESHOOTING
S-6
Causes
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Defective controller calibration data
Defective throttle sensor
HD465-7, HD605-7
20-1171
(10)
TROUBLESHOOTING
S-7
S-7
Exhaust smoke is black (incomplete combustion)
Leakage of air between turbocharger and cylinder head
General causes why exhaust smoke is black Insufficient intake of air Defective condition of fuel injection Excessive injection of fuel Defective HPI sensor Defective HPI actuator Normal output is not applied a See Troubleshooting S-6
Seized turbocharger, interference
Causes
Improper adjustment of valve clearance
Failure timing rail pressure sensor Replace
Confirm recent repair history Degree of use of machine Color of exhaust gas Questions Non-specified fuel is being used Engine oil must be added more frequently Power was lost Dust indicator is red Muffler is crushed Leakage of air between turbocharger and head, loose clamp
Operated for long period Suddenly became black Gradually became black Blue under light load
Suddenly Gradually
Check items
Noise of interference is heard from around turbocharger Clanging sound is heard from around cylinder head Exhaust noise is abnormal Engine pickup is poor and combustion is irregular Blow-by gas is excessive Inspect air cleaner directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low
Troubleshooting
Inspect valve clearance directly When muffler is removed, exhaust sound improves Inspect between turbocharger and cylinder head directly When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low Abnormality in timing rail pressure sensor system is indicated (*2) Inspect sensor directly (Output voltage) Inspect actuator directly (Resistance and filter for clogging) Replace Replace Replace Replace Replace Replace Replace
Remedy
20-1172
(10)
HD465-7, HD605-7
Replace
Correct
Adjust
Clean
Crushed, clogged muffler
Defective fuel pump
Defective injector
TROUBLESHOOTING
S-7
(*1) If the following failure codes are displayed, carry out the troubleshooting in "ENG mode". (If any of the following failure codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C112LK]: Abnormality in timing rail actuator (*2) If an failure code of the timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode".
HD465-7, HD605-7
20-1173
(10)
TROUBLESHOOTING
S-8
S-8
Oil consumption is excessive (or exhaust smoke is blue)
a To prevent the oil from leaking up or down in the turbocharger, do not run the engine at idle for more than 20 minutes continuously (both low and high idle). General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of parts in lubrication system
Dust sucked in from intake system
Causes
Worn seal at turbine end
Worn seal at blower end
Worn, damaged valve (stem, guide, seal)
Confirm recent repair history Questions Degree of use of machine Operated for long period Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Oil level is above H level on gauge Outside of engine is dirty with oil There are loose piping clamps in intake system Inside of turbocharger intake pipe is dirty with oil Check items Inside of exhaust pipe is dirty with oil There is oil in engine coolant Oil level in clutch chamber or damper chamber rises Exhaust smoke is blue under light load Amount of blow-by gas Excessive None
When intake manifold is removed, dust is found inside Troubleshooting Excessive play of turbocharger shaft When intake manifold is removed, inside is found to be dirty with oil When compression pressure is measured, it is found to be low Inspect breather element directly Inspect rear oil seal directly There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Replace Replace Replace Replace Replace Correct Correct Correct Correct Correct Correct Correct
Remedy
Turbocharger
HD465-7, HD605-7
20-1175
(10)
Correct
Clean
Leakage from oil pan or cylinder head
Clogged breather or breather hose
Leakage from oil filter or oil cooler
Leakage from oil drain plug
Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping
Broken piston ring
Broken oil cooler
TROUBLESHOOTING
S-9
S-9
Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Defective combustion Improper fuel used Operation under excessive load Oil change interval is too long
Clogged turbocharger lubrication drain tube Defective seal at turbocharger turbine end
Causes
Clogged breather, breather tube
Worn valve (stem, guide, seal)
Defective oil filter safety valve Replace
Too much engine oil added
Confirm recent repair history Questions Degree of use of machine Operated for long period Non-specified oil is being used Engine oil must be added more frequently Oil level is above H level on gauge When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Check items
Even when engine oil temperature rises, oil filter warning lamp lights up (machines equipped with warning lamp)
Engine oil temperature rises quickly Color of exhaust gas Amount of blow-by gas Blue under light load Black Excessive None Carry out Troubleshooting S-7 Replace Replace Replace Replace Correct Clean Clean Clean
Remedy
Inspect turbocharger lubrication drain tube directly Troubleshooting Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather element directly Inspect oil cooler directly Inspect oil filter directly Inspect safety valve directly
20-1176
(10)
HD465-7, HD605-7
Exhaust smoke is black
Clogged oil cooler
Clogged oil filter
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel Defective condition of fuel injection Excessive injection of fuel Defective HPI sensor
Causes
Defective atmospheric pressure sensor Replace
Leakage of fuel inside head cover
Confirm recent repair history Degree of use of machine Questions Condition of fuel consumption Operated for long period More than for other machines of same model Gradually increased Suddenly increased There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Check items When engine is cranked with starting motor, and Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Exhaust smoke color Black White
Inspect inside of head cover directly When negative pressure at inlet port of fuel pump is measured, it is found to be high Troubleshooting Inspect fuel pump directly When temperature of injector of each cylinder is measured, there are some cylinders that are low When pressure at outlet port of fuel pump is measured, it is found to be low Abnormality in fuel rail pressure sensor system is indicated (*1) Abnormality in timing rail pressure sensor system is indicated (*1) When flow of return fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage) Replace Replace Replace Replace Replace Correct Clean
Remedy
HD465-7, HD605-7
20-1177
(10)
Clean
(*1) If an failure code of the fuel rail pressure sensor system or timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode".
Replace
Defective fuel pump
Defective injector
TROUBLESHOOTING
S-11
S-11 Oil is in coolant, or water spurts back, or coolant level goes down
General causes why oil is in coolant Internal leakage in lubrication system Internal leakage in cooling system
Causes
Broken power train oil cooler (troubleshooting for machine)
Damaged cylinder liner O-ring, holes caused by pitting
Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring Replace
Confirm recent repair history Questions Degree of use of machine Oil level Operated for long period Suddenly increased Gradually increased
Hard water is being used as coolant (or corrosion resistor valve is closed)
Check items
Excessive air bubbles inside radiator, spurts back Engine oil level has risen, oil is cloudy white Hydraulic oil, transmission oil on machine side is cloudy white When hydraulic oil, transmission oil on machine side is drained, water is found Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect cylinder liner directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Replace Replace Replace Replace Replace
Remedy
Troubleshooting
Broken water pump seal
20-1178
(10)
HD465-7, HD605-7
Replace
TROUBLESHOOTING
S-12
S-12 Oil pressure warning lamp lights up (drop in oil pressure)

General causes why oil pressure warning lamp lights up Leakage, clogging, wear of lubricating system Defective oil pressure control Improper selection of fuel (insufficient viscosity) Deterioration of oil due to overheating
Causes
Clogged, broken oil pump suction pipe
Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping
Clogged oil pan suction strainer
Defective oil pump relief valve
Confirm recent repair history Questions Degree of use of machine Non-specified oil is being used Replacement of filters has not been carried out according to Operation Manual Engine oil pressure warning lamp lights up Lights up at low idle Condition when oil pressure warning lamp lights up. Lights up at low, high idle Lights up on slopes Sometimes lights up Check items Oil level warning lamp lights up (machines equipped with warning lamp) There is crushing, external leakage from hydraulic piping Oil level in oil pan is low Oil is cloudy white or smells of diesel oil When oil is drained, metal particles are found When oil filter is inspected, metal particles are found Carry out Troubleshooting S-13 Inspect oil filter directly Troubleshooting Inspect suction strainer, pipe directly Oil pump rotation is heavy, there is play Inspect relief valve, regulator valve directly Inspect oil filter directly When engine oil level sensor is replaced, oil pressure warning lamp goes out (machines equipped with oil level sensor) When oil pressure is measured, it is found to be normal Replace Replace Correct Correct Adjust Clean Clean Clean Clean
Remedy
Replace
HD465-7, HD605-7
20-1179
(10)
Replace
Add
Defective oil pressure sensor
Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler
Coolant, fuel in oil
Clogged oil filter
TROUBLESHOOTING
S-13
S-13 Oil level rises

General causes why oil level rises Coolant in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of coolant or oil from other component
Damaged cylinder liner O-ring, holes caused by pitting
Causes
Clogged water pump drain hole (breather hole), defective seal
Questions
Confirm recent repair history Degree of use of machine Engine oil smells of diesel fuel There is oil in coolant (*1) When engine is first started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or coolant (*1) spurts back Operated for long period Fuel must be added more frequently
Check items
Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level goes down in clutch or damper chamber Oil level goes down in hydraulic tank When compression pressure is measured, it is found to be low Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect rear oil seal directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Inspect thermostat directly Inspect fuel pump directly Inspect injector directly Inspect pump auxiliary equipment (pump, compressor) directly Replace Replace Replace Replace Replace Replace Replace
Remedy
Troubleshooting
(*1) If there is oil in coolant, carry out Troubleshooting S-11.
20-1180
(10)
HD465-7, HD605-7
Replace
Correct
Correct
Correct
Defective auxiliary equipment (pump, compressor) seal
Defective cylinder head injector sleeve
Broken, broken rear oil seal face
Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal
Defective fuel pump seal
TROUBLESHOOTING
S-14
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Rise in oil temperature in power train (troubleshooting for machine) a See the manual for the machine.
Causes Rise in power train oil temperature (troubleshooting for machine) Carry out troubleshooting of machine Replace Replace Replace Replace Replace Replace Replace Damaged cylinder liner O-ring, holes caused by pitting
Defective radiator cap (pressure valve)
Confirm recent repair history Degree of use of machine Questions Condition of overheating Coolant temperature gauge Operated for long period Suddenly overheated Always tends to overheat Rises quickly Does not go down from red range
Radiator coolant level warning lamp lights up (machines equipped with warning lamp) Engine oil level has risen, oil is cloudy white Cloudy white oil is floating on coolant Excessive air bubbles inside radiator, coolant spurts back When light bulb is held behind radiator, no light passes through Check items Radiator shroud, inside of underguard are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose Fan belt whines under sudden load Coolant flows out from overflow hose Power train oil temperature enters red range faster than engine coolant temperature When compression pressure is measured, it is found to be low Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Troubleshooting Inspect oil cooler directly Inspect radiator core directly When temperature difference between top and bottom radiator tanks is measured, it is found to be slight Carry out function test on radiator cap (cracking pressure) When temperature difference between top and bottom radiator tanks is measured, it is found to be excessive Carry out function test on thermostat (cracking temperature) When coolant temperature is measured, it is found to be normal
Remedy
HD465-7, HD605-7
20-1181
(10)
Replace
Correct
Correct
Correct
Add
Defective coolant temperature gauge
Defective operation of thermostat
Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core
Broken water pump
Lack of coolant
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made

General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion noise Air sucked in from intake system
Broken dynamic valve system (valve, rocker arm, etc.)
Causes Air leakage from auxiliary equipment (pump, compressor) Replace
Defect inside muffler (dividing board out of position)
Leakage of air between turbocharger and head
Seized turbocharger, internal interference (*1)
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference Correct
Defective adjustment of valve clearance
Missing, seized gear bushing
Improper gear train backlash
Seized crankshaft bearing
Confirm recent repair history Degree of use of machine Questions Condition of abnormal noise Non-specified fuel is being used Engine oil must be added more frequently Seal on injection pump has come off Metal particles are found in oil filter Leakage of air between turbocharger and head, loose clamp Noise of interference is heard from around turbocharger Clanging sound is heard from around cylinder head Check items Vibrating noise is heard from around muffler
Operated for long period Gradually occurred Suddenly occurred
Color of exhaust gas
Blue under light load Black
Engine pickup is poor and combustion is abnormal Abnormal noise is loud when accelerating engine Blow-by gas is excessive When turbocharger is rotated by hand, it is found to be heavy Inspect dynamic valve system directly Troubleshooting Inspect valve clearance directly When muffler is removed, abnormal noise disappears When compression pressure is measured, it is found to be low Inspect crankshaft bearing directly Inspect front gear and rear gear directly Inspect cooling fan, belt directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly Replace Replace Replace Replace Replace Replace
Remedy
(*1) Judge if the noise is an internal noise or an external noise.
20-1182
(10)
HD465-7, HD605-7
Replace
Correct
Correct
Adjust
Defective injector
TROUBLESHOOTING
S-16
S-16 Vibration is excessive

a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also. General causes why vibration is excessive Defective parts (abnormal wear, breakage) Improper alignment between engine and chassis Abnormal combustion
Causes
Defective dynamic valve system (valve, rocker arm, etc. stuck)
Internal damage in clutch chamber or damper chamber
Loose engine mounting bolts, broken cushion
Worn front support spigot joint portion
Worn main bearing, connecting rod
Confirm recent repair history Questions Degree of use of machine Condition of vibration Non-specified fuel is being used Metal particles are found in oil filter Metal particles are found when oil is drained Check items Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Inspect main bearing, connecting rod directly Troubleshooting Inspect cam bushing directly Inspect front gear train and rear gear train directly Inspect vibration damper directly Injection pump test shows that injection amount is incorrect Inspect front support spigot joint directly Inspect engine mounting bolts, cushions directly Inspect clutch chamber or damper chamber directly (troubleshooting for machine) Replace Replace Replace Replace Replace Replace Replace
Remedy
Operated for long period Suddenly increased Gradually increased
HD465-7, HD605-7
20-1183
(10)
Replace
Correct
Adjust
(troubleshooting for machine)
Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
Electrical system diagram related to emergency steering control ............................................................. 20-1202 Information in troubleshooting table .......................................................................................................... 20-1203 E-1 Emergency steering system does not operate ................................................................................. 20-1205
HD465-7, HD605-7
20-1201
(11)
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL

20-1202
(11)
HD465-7, HD605-7
TROUBLESHOOTING

Trouble
Related information
Trouble in machine 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 <Troubles in harness> Disconnection Connector is connected imperfectly or harness is broken. Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. Short circuit Possible causes of trouble Independent harnesses are in contact with each other abnormally. (Given numbers are reference numbers, which do <Precautions for troubleshooting> not indicate priority) 1) Method of indicating connector No. and handling of T-adapter 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. If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified. Connect positive (+) lead to pin No. or harness entered on front side. Connect negative () lead to pin No. or harness entered on rear side.
HD465-7, HD605-7
20-1203
(11)
TROUBLESHOOTING
20-1204
(11)
HD465-7, HD605-7
TROUBLESHOOTING
E-1
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE

Trouble Related information 1) When emergency steering switch is pressed, emergency steering system does not operate. 2) Automatic emergency steering system does not operate. aSee Operation and Maintenance Manual, Operation, Testing and adjusting before starting engine, Inspection of emergency steering and Inspection of automatic emergency steering. When parking brake is released, voltage is generated at pin H01 (2). When flow on flow switch is lost and flow switch is turned ON, voltage is generated at pin H01 (1). Cause Standard value in normal state/Remarks on troubleshooting
Defective fuse BT2-(26) or If fuse is broken, circuit probably has ground fault. (Carry out trouble1 BT3-(16) shooting for cause 8.) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective emergency steering switch Terminals of switch Between input terminal output terminal Emergency steering switch ON OFF Resistance Max. 1 z Min. 1 Mz
1) Turn starting switch OFF and disconnect parking brake connector PSW (or HTA). 2) Start engine and apply retarder brake, then carry out troubleshooting. 3 Defective parking brake switch PSW (male) Between (1) (2) Parking brake switch When parking brake is released When parking brake is operated (applied) Resistance Max. 1 z Min. 1 Mz
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state Between inlet terminal from fuse BT2 (26) chassis ground Voltage 20 30V
Defective emergency steering timer
aEven if starting switch is turned ON, parking brake is not released until parking brake switch is turned ON (operated) and OFF once. (While parking brake is released, contacts of parking brake should be connected to each other.) 1) Start engine, charge accumulator, apply retarder brake, and stop engine. 2) Turn starting switch ON. 3) Turn parking brake switch OFF (Release). Between inlet terminal from flow switch chassis ground Between emergency steering relay drive terminal chassis ground Voltage Voltage 20 30V 20 30V
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between switch ground terminal chassis Resistance Max. 1 z ground (GND 2) 1) Turn starting switch ON. 2) Turn emergency steering switch ON and carry out troubleshooting. 5 Defective starting motor Between motor (+) terminal chassis ground Voltage 20 30V aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between motor (-) terminal chassis ground Resistance Max. 1 z
HD465-7, HD605-7
20-1205
(11)
TROUBLESHOOTING
E-1
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch ON. 2) Turn emergency steering switch ON and carry out troubleshooting. Between emergency steering relay terminal B chassis ground Voltage Voltage Voltage 20 30V 20 30V 20 30V
Defective emergency 6 steering relay (Both are same)
Between emergency steering relay terminal M chassis ground Between emergency steering relay drive terminal chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between emergency steering relay ground terResistance Max. 1 z minal chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between emergency steering reResistance Max. 1 z lay terminal M motor (+) terminal Wiring harness between emergency steering reResistance Max. 1 z lay drive terminal timer drive terminal Disconnection in wiring harness (Disconnection in 7 wiring or defective contact in connector) Wiring harness between fuse BT2 (26) timer Resistance Max. 1 z power supply input terminal Wiring harness between fuse BT3 (16) PSW Resistance Max. 1 z (female) (1) Wiring harness between PSW (female) (2) Resistance Max. 1 z CJN H01 (female) (2) Wiring harness between H01 (female) (1) timer Resistance Max. 1 z inlet terminal Wiring harness between emergency steering reResistance Max. 1 z lays (All of 4) Wiring harness between emergency steering reResistance Max. 1 z lay (-) terminal CJK chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between emergency steering reResistance Min. 1 Mz lay terminal M motor (+) terminal Wiring harness between emergency steering reResistance Min. 1 Mz lay drive terminal timer drive terminal Wiring harness between fuse BT2 (26) timer Resistance Min. 1 Mz power supply input terminal Wiring harness between fuse BT3 (16) PSW Resistance Min. 1 Mz (female) (1) Wiring harness between PSW (female) (2) Resistance Min. 1 Mz CJN H01 (female) (2) Wiring harness between H01 (female) (1) timer Resistance Min. 1 Mz inlet terminal
Ground fault in wiring 8 harness (Short circuit with GND circuit)
a If "the emergency steering system operates by itself (while the switch is not turned ON)", check the following possible causes. 1) The emergency steering relay is fixed to the ON position because of some vibration. (Replace the emergency steering relay.) 2) The voltage at the (+) terminal of the emergency steering relay is 20 30 V. (This terminal should be grounded.) 3) The wiring on the M side of the emergency steering relay is in contact with the wiring on the B side. (Open the battery box and check the wiring.) 4) The parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.) 5) The steering flow switch is stuck. (Replace the steering flow switch.)
20-1206
(11)
HD465-7, HD605-7
TROUBLESHOOTING
E-1
a How to distinguish the emergency steering relays and the ordinary battery relay. When the battery box is opened, the 2 relays on the left side (on the front side of the machine) are the emergency steering relays.
HD465-7, HD605-7
20-1207
(11)
TROUBLESHOOTING OF ABS CONTROLLER SYSTEM (ABS MODE) (IF EQUIPPED)

Electrical system diagram related ABS control ........................................................................................ 20-1252 Information in troubleshooting table .......................................................................................................... 20-1254 Phenomenon code table ........................................................................................................................... 20-1255 [D1E5KZ] ABS cut relay: Disconnection or short circuit (KZ)................................................................ 20-1256 [DBC0KK] ABS controller: Supply voltage reduction (KK) ..................................................................... 20-1258 [DBC1KK] ABS controller main power line: Supply voltage reduction (KK) ........................................... 20-1259 [DBC2KK] ABS controller load power line: Supply voltage reduction (KK) ............................................ 20-1260 [DBC3KK] ABS controller battery direct power supply: Supply voltage reduction (KK) ......................... 20-1262 [DBC9KM] ABS controller wire wiring harness: Setting operation error (KM) ........................................ 20-1263 [DBCSKR] ABS controller S-NET communication: Defective communication (KR) ............................... 20-1264 [DDD9KA] ABS system switch: Disconnection (KA) .............................................................................. 20-1265 [DDD9KB] ABS system switch: Short circuit (KB) .................................................................................. 20-1266 [DHU6KX] ABS control valve pressure sensor front wheel right (FR): Outside input signal range (KX) ....................................................................................... 20-1268 [DHU7KX] ABS control valve pressure sensor front wheel left (FL): Outside input signal range (KX) ....................................................................................... 20-1270 [DHU8KX] ABS control valve pressure sensor rear wheel right (RR): Outside input signal range (KX) ....................................................................................... 20-1272 [DHU9KX] ABS control valve pressure sensor rear wheel left (RL): Outside input signal range (KX) ....................................................................................... 20-1274 [dk11KX] Accelerator sensor: Outside input signal range (KX)............................................................ 20-1276 [DLF6KA] Wheel speed sensor front wheel right (FR): Disconnection (KA) ......................................... 20-1278 [DLF7KA] Wheel speed sensor front wheel left (FL): Disconnection (KA) ............................................ 20-1280 [dLF8KA] Wheel speed sensor rear wheel right (RR): Disconnection (KA).......................................... 20-1282 [dLF9KA] Wheel speed sensor rear wheel left (RL): Disconnection (KA)............................................. 20-1284 [DWNDKZ] ABS cut valve (F): Disconnection or short circuit (KZ) ......................................................... 20-1286 [DWNDMA] ABS cut valve (F): Malfunction (MA) .................................................................................... 20-1288 [DWNEKZ] ABS cut valve (R): Disconnection or short circuit (KZ) ......................................................... 20-1290 [DWNEMA] ABS cut valve (R): Malfunction (MA) .................................................................................... 20-1292 [DX21KA] ABS control valve front wheel right (FR): Disconnection (KA).............................................. 20-1293 [DX21KB] ABS control valve front wheel right (FR): Short circuit (KB) ................................................. 20-1294 [DX21KY] ABS control valve front wheel right (FR): Short-circuited to power supply (KY) ................... 20-1295 [DX21MA] ABS control valve front wheel right (FR): Malfunction (MA) ................................................. 20-1296 [DX22KA] ABS control valve front wheel left (FL): Disconnection (KA)................................................. 20-1297 [DX22KB] ABS control valve front wheel left (FL): Short circuit (KB) .................................................... 20-1298 [DX22KY] ABS control valve front wheel left (FL): Short-circuited to power supply (KY)...................... 20-1299 [DX22MA] ABS control valve front wheel left (FL): Malfunction (MA) .................................................... 20-1300 [DX23KA] ABS control valve rear wheel right (RR): Disconnection (KA) .............................................. 20-1301 [DX23KB] ABS control valve rear wheel right (RR): Short circuit (KB).................................................. 20-1302 [DX23KY] ABS control valve rear wheel right (RR): Short-circuited to power supply (KY) ................... 20-1303 [DX23MA] ABS control valve rear wheel right (RR): Malfunction (MA).................................................. 20-1304 [DX24KA] ABS control valve rear wheel left (RL): Disconnection (KA) ................................................. 20-1305 [DX24KB] ABS control valve rear wheel left (RL): Short circuit (KB)..................................................... 20-1306 [DX24KY] ABS control valve rear wheel left (RL): Short-circuited with power supply (KY)................... 20-1307 [DX24MA] ABS control valve rear wheel left (RL): Malfunction (MA)..................................................... 20-1308 [DX25MA] ABS control valve (front wheel system): Malfunction (MA)................................................... 20-1309 [DX26MA] ABS control valve (rear wheel system): Malfunction (MA) ................................................... 20-1310
HD465-7, HD605-7
20-1251
(12)
TROUBLESHOOTING
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
20-1252
(12)
HD465-7, HD605-7
TROUBLESHOOTING
HD465-7, HD605-7
20-1253
(12)
TROUBLESHOOTING

Contents of trouble Contents of trouble detected by machine monitor or controller
Action of machine Action taken by controller to protect system or devices when machine monitor or controller detects troumonitor or controller ble Problem that appears on machine as result of action taken by machine monitor or controller Problem that appears on machine (shown above)
Related information Information related to the 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
<Troubles in wiring harness> Disconnection Connector is connected imperfectly or wiring harness is broken. Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. 2 Hot short Wiring harness, which is not connected to power source (24 V) circuit, is in contact with power source (24 V) circuit. Short circuit Independent wiring harnesses are in contact with each other abnorPossible causes Possible causes of troubles mally. and standard value (Given numbers are refer3 in normal state ence numbers, which do not <Precautions for troubleshooting> indicate priority.) (1) Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as explained below for 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. 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 explained below for troubleshooting, unless otherwise specified. Connect positive (+) lead to pin No. or wiring harness entered on front side. Connect negative (-) lead to pin No. or wiring harness entered on rear side side.
4 (2)
20-1254
(12)
HD465-7, HD605-7
TROUBLESHOOTING
Related circuit diagram
Part of electric circuit diagram related to trouble Connector No.: Indicates (Model - Number of pins) and (Color). Arrows ( ): Indicate rough location of connector in machine.

Phenomenon code KA KB KK KM KR KX KY KZ MA Disconnection is wiring Short circuit Supply voltage reduction Operation or setting error Defective communication Outside input signal range Hot short (short-circuit with power source) Disconnection or short circuit Malfunction Contents
HD465-7, HD605-7
20-1255
(12)
TROUBLESHOOTING
[D1E5KZ]
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code E03
Contents of trouble
Failure code Controller code D1E5KZ ABS
Trouble
ABS cut relay: Disconnection or short circuit on ABS cut relay (KZ)
Excessive current is conducted or no current is conducted as output is generated to ABS cut relay circuit. Current is conducted after the output is turned off.
Action of controller Stops ABS control. ABS doesn't work. Problem that appears on machine Usual brake is operable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS1 (female) (14) Resistance Max. 1 z (Disconnection or defective RABS (female) (1) contact) Between chassis ground wiring harness Resistance Max. 1 z RABS (female) (2) Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. 3) Connect T-adapter. Wiring harness between ABS1 (female) (14), RABS (female) (1) chassis ground Resistance Min. 1 Mz
1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (14), RABS (female) (1) chassis ground 4 Defective ABS cut relay 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (14) Resistance chassis ground 250 350 z Voltage Max. 1 V
Replacing ABS cut relay restores the normal state.
5 Defective ABS controller
20-1256
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[D1E5KZ]
HD465-7, HD605-7
20-1257
(12)
TROUBLESHOOTING
[DBC0KK]
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)

Action code E03 Failure code Controller code DBC0KK ABS Trouble ABS controller: Supply voltage reduction in main and direct supply voltage circuits (KK)
Contents of trouble Both the main supply voltage and direct supply voltage circuits went below 17 V.
Related information
Cause
1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS1. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between ABS1 (female) (8), contact) (16) chassis ground Possible causes and standard value in normal state 2 Defective battery or defective charging
Resistance Max. 1 z
Battery voltage shall be 24 V minimum and specific gravity shall be 1.26. 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (7) ABS1 (female) (8), (16) Wiring harness between ABS1 (female) (9), (17) ABS1 (female) (8), (16) Voltage Voltage 20 30 V 20 30 V
20-1258
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DBC1KK]
[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)
Action code E03
Contents of trouble
Failure code Controller code DBC1KK ABS
Trouble ABS controller main power line: Supply voltage reduction (KK)
Difference of voltage between the main supply voltage circuit and direct supply voltage circuit became 5 V or greater.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS1. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 4) Connect the connector. 1 in normal state (Disconnection or defective 5) Turn on starting switch. contact) Wiring harness between ABS1 (female) (9), (17) ABS1 (female) (8), (16)
Voltage
20 30 V
Related electric circuit diagram
HD465-7, HD605-7
20-1259
(12)
TROUBLESHOOTING
[DBC2KK]
[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)
Action code E03 Failure code Controller code DBC2KK ABS Trouble ABS controller load power line: Voltage reduction in solenoid supply voltage (KK)
Solenoid supply voltage went 17 V or below while controller supply voltage circuit was operating norContents of trouble mally. Action of controller Stops ABS control. ABS doesn't work. Problem that appears on machine Usual brake is operable.
Related information
Cause 1 Defective ABS cut relay Disconnection in wiring harness 1 2 (Disconnection or defective contact)
Standard value in normal state/Remarks on troubleshooting Replace it with other relay to restore normal state. 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. 4) Turn on starting switch. Wiring harness between RABS (female) (5) chassis ground Voltage 20 30 V
1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors RABS and ABS1. Possible causes ness 2 3) Connect T-adapter. and standard value 3 (Disconnection or defective Wiring harness between RABS (female) (3) in normal state contact) Resistance Max. 1 z ABS1 (female) (9), (17) 1) Turn off starting switch. 2) Disconnect connectors ABS1 and ABS2. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (1) ABS1 (female) (8), (16) Wiring harness between ABS2 (female) (12) ABS1 (female) (8), (16) Voltage Voltage 20 30 V 20 30 V
20-1260
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DBC2KK]
HD465-7, HD605-7
20-1261
(12)
TROUBLESHOOTING
[DBC3KK]
[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY VOLTAGE REDUCTION (KK)
Action code E03 Failure code Controller code DBC3KK ABS Trouble ABS controller battery direct power supply: Supply voltage reduction (KK)
Contents of trouble Voltage of battery direct power supply circuit went 5 V or below.
Action of controller Continues ABS control.

Problem that Remains unchanged. appears on machine Related information
Cause
1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS1. 3) Connect T-adapter. ness 1 (Disconnection or defective 4) Turn on starting switch. contact) Possible causes Wiring harness between ABS1 (female) (7) and standard value ABS1 (female) (8), (16) in normal state 1) Turn off starting switch. 2) Disconnect connectors ABS1 and ABS2. 3) Connect T-adapter. 2 Defective ABS controller 4) Turn on starting switch. Wiring harness between ABS2 (female) (12) ABS1 (female) (8), (16)
Voltage
20 30 V
Voltage
20 30 V
20-1262
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DBC9KM]
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION ERROR (KM)
Action code E03
Contents of trouble
Failure code Controller code DBC9KM ABS
Trouble ABS controller wiring harness: Setting operation error (KM)
Connector-check signal to be entered at turning on of starting switch does not match the internal setting of controller.
Related information
Cause Possible causes and standard value in normal state 1 Wrong connection of controller connector
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. Connectors ABS3A and ABS5A are appropriately installed.
1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between ABS5A (female) (1) contact) Resistance Max. 1 z chassis ground
HD465-7, HD605-7
20-1263
(12)
TROUBLESHOOTING
[DBCSKR]
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)

Action code E03 Failure code Controller code DBCSKR ABS Trouble ABS controller S-NET communication: Communication failure (KR)
Contents of trouble Input of communication information from monitor to ABS controller is unavailable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS4. Disconnection in wiring har- 3) Connect T-adapter. ness 4) Connect the connector. 1 (Disconnection or defective 5) Turn on starting switch. contact) Possible causes Wiring harness between ABS4 (female) (6), and standard value (12) chassis ground in normal state 1) Turn off starting switch. 2) Disconnect connector ABS4. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS4 (female) (6), (12) chassis ground
Voltage
69V
Voltage
69V
20-1264
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DDD9KA]
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)

Action code E03 Failure code Controller code DDD9KA ABS Trouble ABS system switch: Disconnection (KA)
Contents of trouble ON-input and OFF-input of ABS system switch were turned off.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connectors ABS and DPC2B. 1 Hot short on wiring harness 3) Connect T-adapter. Wiring harness between DPC2B (female) (2) Resistance Max. 1 z ABS (female) (3) 1) Turn off starting switch. 2) Replace ABS system switch with a normal one. 3) Turn on starting switch. Normal state After replacing ABS system was not restored switch with a normal one: Normal state was restored 1) Turn off starting switch. 2) Disconnect connector DPC2B. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between DPC2B (female) (2) chassis ground Turn on ABS system switch Turn off ABS system switch Voltage Voltage 20 30 V Max. 1 V System switch is normal System switch is defective
Defective ABS system 2 Possible causes switch and standard value in normal state
HD465-7, HD605-7
20-1265
(12)
TROUBLESHOOTING
[DDD9KB]
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)

Action code E03 Failure code Controller code DDD9KB ABS Trouble ABS system switch: Short circuit (KB)
Contents of trouble ON-input and OFF-input of ABS system switch were turned on.
Related information
Cause Ground fault in wiring harness
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS and DPC2B. 3) Connect T-adapter. Wiring harness between DPC2B (female) (2) Resistance Min. 1 Mz ABS (female) (3) 1) Turn off starting switch. 2) Replace ABS system switch with a normal one. 3) Turn on starting switch. Normal state After replacing ABS system was not restored switch with a normal one: Normal state was restored 1) Turn off starting switch. 2) Disconnect connector DPC2B. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between DPC2B (female) (2) chassis ground Turn on ABS system switch Turn off ABS system switch Voltage Voltage 20 30 V Max. 1 V System switch is normal System switch is defective
Defective ABS system 2 Possible causes switch and standard value in normal state
20-1266
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU6KX]
[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR): OUTSIDE INPUT SIGNAL RANGE (KX)
Action code E03
Contents of trouble
Failure code Controller code DHU6KX ABS
ABS control valve pressure sensor front wheel right (FR): Trouble Outside input signal range (KX)
Input voltage to ABS control valve pressure sensor (FR) signal circuit went 0.3 V or below or 4.7 V or above.
Action of controller Stops ABS control.

Problem that ABS doesn't work. appears on machine Usual brake is operable. Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS2, ABS3A and BPFR. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16) Resistance Max. 1 z ness BPFR (female) (1) (Disconnection or defective Wiring harness between ABS3A (female) (9) contact) Resistance Max. 1 z BPFR (female) (3) Wiring harness between ABS2 (female) (16) Resistance Max. 1 z BPFR (female) (2) Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (9), Resistance Min. 1 Mz BPFR (female) (3) chassis ground
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFR. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (9), BPFR (female) (3) chassis ground 4 Defective sensor Voltage Max. 4.7 V
Replacing pressure sensor (Front wheel right: BPFR) with (Front wheel left: BPFL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (9) ABS3A (female) (16) Voltage 0.3 4.7 V
5 Defective ABS control
20-1268
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU6KX]
HD465-7, HD605-7
20-1269
(12)
TROUBLESHOOTING
[DHU7KX]
[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL): OUTSIDE INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DHU7KX ABS Trouble ABS control valve pressure sensor front wheel left (FL): Outside input signal range (KX)
Input voltage to ABS control valve pressure sensor (FL) signal circuit went 0.3 V or below or 4.7 V or Contents of trouble above. Action of controller Stops ABS control. ABS doesn't work. Problem that appears on machine Usual brake is operable.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off the starting switch. 2) Disconnect connectors ABS2, ABS3 and BPFL. 3) Connect T-adapter.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16) Resistance Max. 1 z ness BPFL (female) (1) 1 (Disconnection or defective Wiring harness between ABS3A (female) (10) contact) Resistance Max. 1 z BPFL (female) (3) Wiring harness between ABS2 (female) (16) Resistance Max. 1 z BPFL (female) (2) Ground fault in wiring harness 1) Turn off the starting switch. 2) Disconnect connectors ABS3 and BPFL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (10), Resistance Min. 1 Mz BPFL (female) (3) chassis ground
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFL. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (10), BPFL (female) (3) chassis ground 4 Defective pressure sensor Voltage Max. 4.7 V
Replacing pressure sensor (Front wheel left: BPFL) with (Front wheel right: BPFR) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (10) ABS3A (female) (16) Voltage 0.3 4.7 V
5 Defective ABS control
20-1270
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU7KX]
HD465-7, HD605-7
20-1271
(12)
TROUBLESHOOTING
[DHU8KX]
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR): OUTSIDE INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DHU8KX ABS Trouble ABS control valve pressure sensor rear wheel right (RR): Outside input signal range (KX)
Input voltage to ABS control valve pressure sensor (RR) signal circuit went 0.5 V or below or 4.7 V or Contents of trouble above. Action of controller Stops ABS control. ABS doesn't work. Problem that appears on machine Usual brake is operable.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS1, ABS3A and BPRR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (16) Resistance Max. 1 z BPRR (female) (1) Wiring harness between ABS3A (female) (19) Resistance Max. 1 z BPRR (female) (3) Wiring harness between ABS1 (female) (13) Resistance Max. 1 z BPRR (female) (2)
Disconnection in wiring harness 1 1 (Pressure sensor circuit) (Disconnection or defective contact)
Ground fault in wiring har2 ness (Pressure sensor circuit)
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (19), Resistance Min. 1 Mz BPRR (female) (3) chassis ground
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRR. 3) Connect T-adapter. Hot short on wiring harness 4) Connect the connector. 3 (Pressure sensor circuit) 5) Turn on starting switch. Possible causes and standard value in normal state Wiring harness between ABS3A (female) (19), BPRR (female) (3) chassis ground Voltage Max. 4.7 V
1) Turn off starting switch. 2) Disconnect connectors ABS5A and S01F. Disconnection in wiring har3) Connect T-adapter. ness 2 4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) Resistance Max. 1 z (Disconnection or defective S01F(female) (1) contact) Wiring harness between S01M (male) (2) Resistance Max. 1 z S01F (female) (2) 1) Turn off starting switch. 2) Disconnect connectors ABS5A and BRC5A. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ABS5A (female) (5) 5 (Retarder switch circuit) Resistance Max. 1 z (Disconnection or defective BRC5A (F) (female) (4) contact) Wiring harness between BRC5A (M) (male) (4) Resistance Max. 1 z BRC5A (F) (female) (4) 6 Defective pressure sensor Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel left: BPRL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (19) ABS3A (female) (16) Voltage 0.5 4.7 V
20-1272
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU8KX]
HD465-7, HD605-7
20-1273
(12)
TROUBLESHOOTING
[DHU9KX]
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL): OUTSIDE INPUT SIGNAL RANGE (KX)
Action code E03 Failure code Controller code DHU9KX ABS Trouble ABS control valve pressure sensor rear wheel left (RL): Outside input signal range (KX)
Input voltage to ABS control valve pressure sensor (RL) signal circuit went 0.5 V or below or 4.7 V or Contents of trouble above. Action of controller Stops ABS control. ABS doesn't work. Problem that appears on machine Usual brake is operable.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS1, ABS3A and BPRL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (16) Resistance Max. 1 z BPRL (female) (1) Wiring harness between ABS3A (female) (20) Resistance Max. 1 z BPRL (female) (3) Wiring harness between ABS1 (female) (13) Resistance Max. 1 z BPRL (female) (2)
Disconnection in wiring harness 1 1 (Pressure sensor circuit) (Disconnection or defective contact)
Ground fault in wiring har2 ness (Pressure sensor circuit)
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (20), Resistance Min. 1 Mz BPRL (female) (3) chassis ground
1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRL. 3) Connect T-adapter. Hot short on wiring harness 4) Connect the connector. 3 (Pressure sensor circuit) 5) Turn on starting switch. Possible causes and standard value in normal state Wiring harness between ABS3A (female) (20), BPRL (female) (3) chassis ground Voltage Max. 4.7 V
1) Turn off starting switch. 2) Disconnect connectors ABS5A and S01F. Disconnection in wiring har3) Connect T-adapter. ness 2 4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) Resistance Max. 1 z (Disconnection or defective S01F(female) (1) contact) Wiring harness between S01M (male) (2) Resistance Max. 1 z S01F (female) (2) 1) Turn off starting switch. 2) Disconnect connectors ABS5A and BRC5A. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ABS5A (female) (5) 5 (Retarder switch circuit) Resistance Max. 1 z (Disconnection or defective BRC5A (F) (female) (4) contact) Wiring harness between BRC5A (M) (male) (4) Resistance Max. 1 z BRC5A (F) (female) (4) 6 Defective pressure sensor Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel left: BPRL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (20) ABS3A (female) (16) Voltage 0.5 4.7 V
20-1274
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DHU9KX]
HD465-7, HD605-7
20-1275
(12)
TROUBLESHOOTING
[DK11KX]
[dk11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)

Action code E03 Failure code Controller code dk11KX ABS Trouble Accelerator sensor: Outside input signal range (KX)
Contents of trouble Voltage of accelerator sensor signal circuit went 0.6 V or below or 4.7 V or above.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3B (female) (14) 1 (Disconnection or defective Resistance Max. 1 z BRC3B (F) (female) (11) contact) Wiring harness between BRC3B (M) (male) Resistance Max. 1 z (11) BRC3B (F) (female) (11) 1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. 3) Connect T-adapter. Wiring harness between ABS3B (female) (14), Resistance Min. 1 Mz BRC3B (F) (female)(11), BRC3B (M) (male) (11) chassis ground
1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. 3) Connect T-adapter. 4) Connect the connector. 3 Hot short on wiring harness 5) Turn on starting switch. Wiring harness between ABS3B (female) (14), BRC3B (F) (female)(11), BRC3B (M) (male) (11) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3B (female) (14) ABS3A (female) (16) Voltage 0.6 4.7 V Voltage Max. 4.7 V
4 Defective accelerator sensor Replacing failed accelerator sensor restores the normal state.
20-1276
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DK11KX]
HD465-7, HD605-7
20-1277
(12)
TROUBLESHOOTING
[DLF6KA]
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)
Action code E03 Failure code Controller code DLF6KA ABS Trouble Wheel speed sensor front wheel right (FR): Disconnection (KA)
Contents of trouble Input of pulse signal to wheel speed sensor (FR) signal circuit is unavailable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector WSFR. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSFR (male) (1) WSFR (male) (2)
Resistance
1,150 1,450 z
1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFR. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (2) 2 (Disconnection or defective Resistance Max. 1 z WSFR (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z WSFR (female) (2) Possible causes and standard value in normal state 1) Turn off starting switch.Connect the connector.Connect the connector. 2) Disconnect connectors ABS3A and WSFR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (2), Resistance Min. 1 Mz WSFR (female) (1) chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSFR (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFR. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (2), WSFR (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (2) Resistance ABS3A (female) (14) 1,150 1,450 z Voltage Max. 5 V
20-1278
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF6KA]
HD465-7, HD605-7
20-1279
(12)
TROUBLESHOOTING
[DLF7KA]
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA)
Action code E03 Failure code Controller code DLF7KA ABS Trouble Wheel speed sensor front wheel left (FL): Disconnection (KA)
Contents of trouble Input of pulse signal to wheel speed sensor (FL) signal circuit is unavailable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector WSFL. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSFL(male) (1) WSFL (male) (2)
Resistance
1,150 1,450 z
1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (3) 2 (Disconnection or defective Resistance Max. 1 z WSFL (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z WSFL (female) (2) Possible causes and standard value in normal state 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (3), Resistance Min. 1 Mz WSFL (female) (1) chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSFL (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (3), WSFL (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (3) Resistance ABS3A (female) (14) 1,150 1,450 z Voltage Max. 5 V
20-1280
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF7KA]
HD465-7, HD605-7
20-1281
(12)
TROUBLESHOOTING
[DLF8KA]
[dLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA)
Action code E03 Failure code Controller code dLF8KA ABS Trouble Wheel speed sensor rear wheel right (RR): Disconnection (KA)
Contents of trouble Input of pulse signal to wheel speed sensor (RR) signal circuit is unavailable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector WSRR2. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSRR2 (male) (1) Resistance WSRR2 (male) (2)
1,150 1,450 z
1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (12) 2 (Disconnection or defective Resistance Max. 1 z WSRR2 (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z WSRR2 (female) (2) Possible causes and standard value in normal state 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. 3) Connect T-adapter. Wiring harness between ABS3A (female) (12), Resistance Min. 1 Mz WSRR2 (female) (1) chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSRR2 (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (12), WSRR2 (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (12) ABS3A (female) (14) Resistance 1,150 1,450 z Voltage Max. 5 V
20-1282
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF8KA]
HD465-7, HD605-7
20-1283
(12)
TROUBLESHOOTING
[DLF9KA]
[dLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)
Action code E03 Failure code Controller code dLF9KA ABS Trouble Wheel speed sensor rear wheel left (RL): Disconnection (KA)
Contents of trouble Input of pulse signal to wheel speed sensor (RL) signal circuit is unavailable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector WSRL2. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (RL) Wiring harness between WSRL2 (male) (1) Resistance WSRL2 (male) (2)
1,150 1,450 z
1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (13) 2 (Disconnection or defective Resistance Max. 1 z WSRL2 (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z WSRL2 (female) (2) Possible causes and standard value in normal state 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. 3) Connect T-adapter. Wiring harness between ABS3A (female) (13), Resistance Min. 1 Mz WSRL2 (female) (1) chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSRL2 (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (13), WSRL2 (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (13) ABS3A (female) (14) Resistance 1,150 1,450 z Voltage Max. 5 V
20-1284
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DLF9KA]
HD465-7, HD605-7
20-1285
(12)
TROUBLESHOOTING
[DWNDKZ]
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code E03
Contents of trouble
Failure code Controller code DWNDKZ ABS
Trouble ABS cut valve (F): Disconnection or short circuit (KZ)
Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (F) circuit. Current is conducted after the output is turned off.
Action of controller Stops ABS control (front wheels). ABS doesn't work (front wheels). Problem that appears on machine Usual brake is operable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS 1(female) (1) 1 (Disconnection or defective CVF (female) (1) contact) Wiring harness between CVF (female) (2) chassis ground Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. 3) Connect T-adapter. Wiring harness between ABS1 (female) (1), CVF (female) (1) chassis ground
Resistance Min. 1 Mz
1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (1), CVF (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (1) chassis ground Resistance 10 30 z Voltage Max. 1 V
4 Defective ABS cut valve (F): Replacing ABS cut valve (F) restores the normal state.
20-1286
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNDKZ]
HD465-7, HD605-7
20-1287
(12)
TROUBLESHOOTING
[DWNDMA]
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)

Action code E03 Failure code Controller code DWNDMA ABS Trouble ABS cut valve (F): Malfunction (MA)
Contents of trouble ABS cut valve (F) does not operate normally.
Action of controller Stops ABS control (front wheel). ABS doesn't work (front wheels). Problem that appears on machine Usual brake is operable.
Related information
Cause Defective ABS cut valve 1 pressure switch (F)
Standard value in normal state/Remarks on troubleshooting Replacing it with ABS cut valve pressure switch (R) restores the normal state.
2 Defective ABS cut valve (F) Replacing ABS cut valve (F) restores the normal state. 1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSF. Possible causes 3) Connect T-adapter. and standard value 3 ness (Disconnection or defective in normal state Wiring harness between ABS5A (female) (2) contact) Resistance Max. 1 z CVSF (female) (1) Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS5A and CVSF. 3) Connect T-adapter. Wiring harness between ABS5A (female) (2), Resistance Min. 1 Mz CVSF (female) (1) chassis ground
20-1288
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNEKZ]
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code E03
Contents of trouble
Failure code Controller code DWNEKZ ABS
Trouble ABS cut valve (R): Disconnection or short circuit (KZ)
Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (R) circuit. Current is conducted after the output is turned off.
Action of controller Stops ABS control (rear wheels). ABS doesn't work (rear wheels). Problem that appears on machine Usual brake is operable.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS1 (female) (10) 1 (Disconnection or defective Resistance Max. 1 z RABS2 (female) (1) contact) Wiring harness between RABS2 (female) (2) Resistance Max. 1 z chassis ground Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. 3) Connect T-adapter. Wiring harness between ABS1 (female) (10), RABS2 (female) (1) chassis ground Resistance Min. 1 Mz
1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (10), RABS2 (female) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (10) Resistance 10 30z chassis ground Voltage Max. 1 V
4 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.
20-1290
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DWNEKZ]
HD465-7, HD605-7
20-1291
(12)
TROUBLESHOOTING
[DWNEMA]
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)

Action code E03 Failure code Controller code DWNEMA ABS Trouble ABS cut valve (R): Malfunction (MA)
Contents of trouble ABS cut valve (R) does not operate normally.
Related information
Cause Defective ABS cut valve 1 pressure switch (R)
Standard value in normal state/Remarks on troubleshooting Replacing it with ABS cut valve pressure switch (F) restores the normal state.
2 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state. 1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSR. Possible causes ness 3) Connect T-adapter. and standard value 3 (Disconnection or defective Wiring harness between ABS5A (female) (3) in normal state contact) Resistance Max. 1 z CVSR (female) (1) Ground fault in wiring harness 1) Turn off starting switch. 2) Disconnect connectors ABS5A and CVSR. 3) Connect T-adapter. Wiring harness between ABS5A (female) (3) , Resistance Min. 1 Mz CVSR (female) (1) chassis ground
20-1292
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX21KA]
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)
Action code E03 Failure code Controller code DX21KA ABS Trouble ABS control valve front wheel right (FR): Disconnection (KA)
Contents of trouble Current is not conducted as output is generated to ABS control valve (FR) circuit.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (7) Resistance Max. 1 z (Disconnection or defective ABSFR (female) (1) contact) Wiring harness between ABS2 (female) (17) Resistance Max. 1 z ABSFR (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSFR. Defective ABS control valve 3) Connect T-adapter. 2 (FR) Across terminals between ABSFR (male) (1) Resistance 10 30 z ABSFR (male) (2) 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (7) Resistance 10 30 z ABS2 (female) (17)
HD465-7, HD605-7
20-1293
(12)
TROUBLESHOOTING
[DX21KB]
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DX21KB ABS Trouble ABS control valve front wheel right (FR): Short circuit (KB)
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (FR) circuit.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. 3) Connect T-adapter. Wiring harness between ABS2 (female) (7) chassis ground Resistance Min. 1 Mz
Wiring harness between ABS2 (female) (17) Resistance Min. 1 Mz chassis ground Possible causes and standard value in normal state 2 1) Turn off starting switch. 2) Disconnect connector ABSFR. 3) Connect T-adapter.
Defective ABS control valve Across terminals between ABSFR (male) (1) Resistance 10 30 z (FR) ABSFR (male) (2) Wiring harness between ABSFR (male) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (7) Resistance 10 30 z ABS2 (female) (17) Resistance Min. 1 Mz
20-1294
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX21KY]
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO POWER SUPPLY (KY)
Action code E03 Failure code Controller code DX21KY ABS Trouble ABS control valve front wheel right (FR): Short-circuited with power supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (FR) circuit is turned off.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (7), ABSFR (female) (1) chassis ground Wiring harness between ABS2 (female) (17), ABSFR (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (7) Resistance 10 30 z ABS2 (female) (17) Voltage Voltage Max. 1 V Max. 1 V
1 Hot short on wiring harness
HD465-7, HD605-7
20-1295
(12)
TROUBLESHOOTING
[DX21MA]
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA)
Action code E03 Failure code Controller code DX21MA ABS Trouble ABS control valve front wheel right (FR): Malfunction (MA)
Contents of trouble ABS cut valve (FR) does not operate normally.
Related information
Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FL) restores the and standard value 1 pressure sensor (FR) normal state. in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FL) restores the normal state. (FR)
20-1296
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX22KA]
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)
Action code E03 Failure code Controller code DX22KA ABS Trouble ABS control valve front wheel left (FL): Disconnection (KA)
Contents of trouble Current is not conducted as output is generated to ABS control valve (FL) circuit.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (8) Resistance Max. 1 z (Disconnection or defective ABSFL (female) (1) contact) Wiring harness between ABS2 (female) (18) Resistance Max. 1 z ABSFL (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSFL. Defective ABS control valve 3) Connect T-adapter. 2 (FL) Across terminals between ABSFL (male) (1) Resistance 10 30 z ABSFL (male) (2) 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (8) Resistance 10 30 z ABS2 (female) (18)
HD465-7, HD605-7
20-1297
(12)
TROUBLESHOOTING
[DX22KB]
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DX22KB ABS Trouble ABS control valve front wheel left (FL): Short circuit (KB)
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (FL) circuit.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. 3) Connect T-adapter. Wiring harness between ABS2 (female) (8) chassis ground Resistance Min. 1 Mz
Wiring harness between ABS2 (female) (18) Resistance Min. 1 Mz chassis ground Possible causes and standard value in normal state 2 1) Turn off starting switch. 2) Disconnect connector ABSFL. 3) Connect T-adapter.
Defective ABS control valve Across terminals between ABSFL (male) (1) Resistance 10 30 z (FL) ABSFL (male) (2) Wiring harness between ABSFL (male) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (8) Resistance 10 30 z ABS2 (female) (18) Resistance Min. 1 Mz
20-1298
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX22KY]
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO POWER SUPPLY (KY)
Action code E03 Failure code Controller code DX22KY ABS Trouble ABS control valve front wheel left (FL): Short-circuit to power supply
Contents of trouble Current is conducted after output to ABS control valve (FL) circuit is turned off.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (8), ABSFL (female) (1) chassis ground Wiring harness between ABS2 (female) (18), ABSFL (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (8) Resistance 10 30 z ABS2 (female) (18) Voltage Voltage Max. 1 V Max. 1 V
HD465-7, HD605-7
20-1299
(12)
TROUBLESHOOTING
[DX22MA]
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)
Action code E03 Failure code Controller code DX22MA ABS Trouble ABS control valve front wheel left (FL): Malfunction (MA)
Contents of trouble ABS cut valve (FL) does not operate normally.
Related information
Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FR) restores the and standard value 1 normal state. pressure sensor (FL) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FR) restores the normal state. (FL)
20-1300
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX23KA]
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)
Action code E03 Failure code Controller code DX23KA ABS Trouble ABS control valve rear wheel right (RR): Disconnection (KA)
Contents of trouble Current is not conducted as output is generated to ABS control valve (RR) circuit.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (9) Resistance Max. 1 z (Disconnection or defective ABSRR (female) (1) contact) Wiring harness between ABS2 (female) (19) Resistance Max. 1 z ABSRR (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSRR. Defective ABS control valve 3) Connect T-adapter. 2 (RR) Across terminals between ABSRR (male) (1) Resistance 10 30 z ABSRR (male) (2) 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (9) Resistance 10 30 z ABS2 (female) (19)
HD465-7, HD605-7
20-1301
(12)
TROUBLESHOOTING
[DX23KB]
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DX23KB ABS Trouble ABS control valve rear wheel right (RR): Short circuit (KB)
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (RR) circuit.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. 3) Connect T-adapter. Wiring harness between ABS2 (female) (9) chassis ground Resistance Min. 1 Mz
Wiring harness between ABS2 (female) (19) Resistance Min. 1 Mz chassis ground Possible causes and standard value in normal state 2 1) Turn off starting switch. 2) Disconnect connector ABSRR. 3) Connect T-adapter.
Defective ABS control valve Across terminals between ABSRR (male) (1) Resistance 10 30 z (FR) ABSRR (male) (2) Wiring harness between ABSRR (male) (1) Resistance Min. 1 Mz chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (9) Resistance 10 30 z ABS2 (female) (19)
20-1302
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX23KY]
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO POWER SUPPLY (KY)
Action code E03 Failure code Controller code DX23KY ABS Trouble ABS control valve rear wheel right (RR): Short-circuited to power supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (RR) circuit is turned off.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (9), ABSRR (female) (1) chassis ground Wiring harness between ABS2 (female) (19), ABSRR (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (9) Resistance 10 30 z ABS2 (female) (19) Voltage Voltage Max. 1 V Max. 1 V
HD465-7, HD605-7
20-1303
(12)
TROUBLESHOOTING
[DX23MA]
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)
Action code E03 Failure code Controller code DX23MA ABS Trouble ABS control valve rear wheel right (RR): Malfunction (MA)
Contents of trouble ABS control valve (RR) does not operate normally.
Related information
Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RL) restores the and standard value 1 normal state. pressure sensor (RR) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (RL) restores the normal state. (RR)
20-1304
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX24KA]
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA)
Action code E03 Failure code Controller code DX24KA ABS Trouble ABS control valve rear wheel left (RL): Disconnection (KA)
Contents of trouble Current is not conducted as output is generated to ABS control valve (RL) circuit.
Related information
Cause
1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (10) Resistance Max. 1 z (Disconnection or defective ABSRL (female) (1) contact) Wiring harness between ABS2 (female) (20) Resistance Max. 1 z ABSRL (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSRL. Defective ABS control valve 3) Connect T-adapter. 2 (RL) Across terminals between ABSRL (male) (1) Resistance 10 30 z ABSRL (male) (2) 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (10) Resistance 10 30 z ABS2 (female) (20)
HD465-7, HD605-7
20-1305
(12)
TROUBLESHOOTING
[DX24KB]
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB)
Action code E03 Failure code Controller code DX24KB ABS Trouble ABS control valve rear wheel left (RL): Short circuit (KB)
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (RL) circuit.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. 3) Connect T-adapter. Wiring harness between ABS2 (female) (10) Resistance Min. 1 Mz chassis ground Wiring harness between ABS2 (female) (20) Resistance Min. 1 Mz chassis ground
Possible causes and standard value in normal state 2
Defective ABS control valve Across terminals between ABSRL (male) (1) Resistance 10 30 z (RL) ABSRL (male) (2) Wiring harness between ABSRL (male) (1) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (10) Resistance 10 30 z ABS2 (female) (20) Resistance Min. 1 Mz
1) Turn off starting switch. 2) Disconnect connector ABSRL. 3) Connect T-adapter.
20-1306
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX24KY]
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH POWER SUPPLY (KY)
Action code E03 Failure code Controller code DX24KY ABS Trouble ABS control valve rear wheel left (RL): Short-circuited with power supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (RL) circuit is turned off.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (10), ABSRL (female) (1) chassis ground Wiring harness between ABS2 (female) (20), ABSRL (female) (2) chassis ground 1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (10) Resistance 10 30 z ABS2 (female) (20) Voltage Voltage Max. 1 V Max. 1 V
HD465-7, HD605-7
20-1307
(12)
TROUBLESHOOTING
[DX24MA]
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)
Action code E03 Failure code Controller code DX24MA ABS Trouble ABS control valve rear wheel left (RL): Malfunction
Contents of trouble ABS control valve (RL) does not operate normally.
Related information
Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RR) restores the and standard value 1 normal state. pressure sensor (RL) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FR) restores the normal state. (RL)
20-1308
(12)
HD465-7, HD605-7
TROUBLESHOOTING
[DX25MA]
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)

Action code E03 Failure code Controller code DX25MA ABS Trouble ABS control valve (front wheel system): Malfunction (MA)
Contents of trouble ABS control valve (FR) or ABS control valve (FL) does not operate normally.
Related information
Cause Defective ABS control valve (FR) Possible causes Defective ABS control valve and standard value (FL) in normal state 1 Defective ABS control valve pressure sensor (FR) Defective ABS control valve pressure sensor (FL)
Turn on ABS system check and locate from the failure code (DX21MA and DX22MA) which of front wheel right or left is responsible for malfunction of ABS control valve. After confirmation, inspect and repair the valve according to the failure code.
HD465-7, HD605-7
20-1309
(12)
TROUBLESHOOTING
[DX26MA]
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)

Action code E03 Failure code Controller code DX26MA ABS Trouble ABS control valve (rear wheel system): Malfunction (MA)
Contents of trouble ABS control valve (RR) or ABS control valve (RL) does not operate normally.
Related information
Cause Defective ABS control valve (RR) Possible causes Defective ABS control valve and standard value (RL) in normal state 1 Defective ABS control valve pressure sensor (RR) Defective ABS control valve pressure sensor (RL)
Turn on ABS system check and locate from the failure code (DX23MA and DX24MA) which of front wheel right or left is responsible for malfunction of ABS control valve. After confirmation, inspect and repair the valve according to the failure code.
20-1310
(12)
HD465-7, HD605-7
30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL ...................30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION .......................................30- 4 SPECIAL TOOL LIST................................. 30-5-1 SKETCH OF SPECIAL TOOL.................... 30-5-4 FUEL INJECTION PUMP Removal and Installation ..........................30- 6 RADIATOR Removal....................................................30- 7 Installation.................................................30- 8 ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER Removal and Installation ..........................30- 9 ENGINE FRONT SEAL Removal and Installation ..........................30-10 OUTPUT SHAFT Removal and Installation ..........................30-11 Disassembly .............................................30-12 Assembly ..................................................30-13 ENGINE REAR SEAL Removal and Installation ..........................30-15 CYLINDER HEAD Removal....................................................30-17 Installation.................................................30-19 ENGINE Removal....................................................30-22 Installation.................................................30-24 TORQUE CONVERTER AND TRANSMISSION Removal....................................................30-25 Installation.................................................30-27 TRANSMISSION AND TORQUE CONVERTER Separation and Coupling ..........................30-28 TORQUE CONVERTER Disassembly .............................................30-29 Assembly ..................................................30-33 TRANSMISSION Disassembly .............................................30-39 Assembly ..................................................30-52 DIFFERENTIAL Removal....................................................30-67 Installation.................................................30-68 Disassembly .............................................30-69 HD465-7, HD605-7 Assembly.................................................. 30-73 FRONT WHEEL Removal and Installation.......................... 30-81 REAR WHEEL Removal ................................................... 30-82 Installation ................................................ 30-83 FRONT BRAKE CALIPER PADS Removal and Installation.......................... 30-84 FRONT BRAKE CALIPERS Removal and installation .......................... 30-85 Disassembly and Assembly ..................... 30-86 FRONT WHEEL HUB Disassembly............................................. 30-88 Assembly.................................................. 30-89 FINAL DRIVE CARRIER Removal and installation .......................... 30-91 Disassembly and Assembly ..................... 30-92 FINAL DRIVE AND REAR BRAKE Removal ................................................... 30-93 Installation ................................................ 30-95 FINAL DRIVE, REAR BRAKE AND PARKING BRAKE Removal and Installation ......................... 30-97 Disassembly............................................. 30-98 Assembly................................................ 30-103 FRONT SUSPENSION CYLINDER Removal ................................................. 30-109 Installation .............................................. 30-110 Disassembly (Standard cylinder).............30-111 Assembly (Standard cylinder) ................ 30-112 Disassembly (Cylinder with buffer ring) .. 30-113-1 Assembly (Cylinder with buffer ring) ... 30-113-2 REAR SUSPENSION CYLINDER Removal and Installation........................ 30-114 Disassembly (Standard cylinder)............ 30-115 Assembly (Standard cylinder) ................ 30-116 Disassembly (Cylinder with buffer ring) .. 30-117-1 Assembly (Cylinder with buffer ring) ... 30-117-2 RETARDER COOLING PUMP Removal and Installation........................ 30-118
30-1
(10)
STEERING, HOIST, AND HOIST CONTROL PUMP Removal and Installation ........................30-119 TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP Removal and Installation ........................30-120 STEERING VALVE Removal and Installation ........................30-121 Disassembly ...........................................30-122 Assembly ................................................30-125 DEMAND VALVE Removal and Installation ........................30-132 HOIST VALVE Removal and Installation ........................30-133 STEERING CYLINDER Disassembly ...........................................30-134 Assembly ................................................30-135 HOIST CYLINDER Disassembly ...........................................30-137 Assembly ................................................30-138 DUMP BODY Removal..................................................30-141 Installation...............................................30-142 OPERATOR'S SEAT Disassembly ...........................................30-144 Assembly ................................................30-149
30-2
(10)
HD465-7, HD605-7
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. Any special techniques applying only to the installation procedure are marked , and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF ASSEMBLY .....Title of operation ..............................................................Precautions related to safety when carrying out the operation 1. X X X X (1) ...........................................Step in operation ...........................................................Technique or important point to remember when removing XXXX (1). 2. 3. (2): .................................... assembly (3) ..................................................Quantity of oil or water drained INSTALLATION OF cccc ASSEMBLY ....Title of operation Carry out installation in the reverse order to removal. ....................................................Technique used during installation ...........................................................Technique or important point to remember when installing (2). Adding water, oil ...............................Step in operation ...........................................................Point to remember when adding water or oil ...................................................Quantity when filling with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual. Indicates that a technique is listed for use during installation
HD465-7, HD605-7
30-3
PRECAUTIONS WHEN CARRYING OUT OPERATIONL
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes
Nominal number 02 03 04 05 06 Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 Nut (elbow end) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628
2)
Split flange type hoses and tubes

Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used.
Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
30-4
HD465-7, HD605-7
PRECAUTIONS WHEN CARRYING OUT OPERATION
1.
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. 2. Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HD465-7, HD605-7
30-5
SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79 Tcan not be supplied (they are items to be locally manufactured). a Necessity: t : .......Cannot be substituted, should always be installed (used) q : .......Extremely useful if available, can be substituted with commercially available part. New/remodel:N : .......Tools with new part numbers, newly developed for this model. R : .......Tools with upgraded part numbers, remodeled from items already available for other models. Blank....Tools already available for other models, used without any modification a Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Component Symbol Part No. 795-799-5410 A 795-799-5420 795-621-1140 A2 795-902-1460 01582-02218 Engine assembly A3 01050-32280 792-420-1110 792-420-1120 C4 790-413-1120 01010-51230 790-501-5000 1 Torque convertor assembly C 2 3 790-901-2110 790-901-3011 790-101-1871 792-103-5110 792-420-1110 Torque convertor transmission assembly 792-420-1120 C4 790-413-1120 01010-51230 Transmission assembly D1 799-301-1600 790-501-5000 1 Diffelential assembly H 790-901-3420 2 790-425-1660 Plate Wrench 790-901-5110 Color Bolt Oil leak tester Unit repair stand Bracket 1 8 Color Bolt Unit repair stand Bracket Plate Nut wrench Wrench Centering tool Flange 1 8 Bolt Centering tool Flange 795-621-1130 Remover Push tool Bolt Nut Push tool Part Name Adapter
New/ SkeNece remo -ssity Qty del tch
Nature of work, remarks Removal, installation of injector assembly
t t t t t t t t
1 1 1 3 3 1
Installation of engine front seal
Installation of engine rear seal 5 1 2 Centring engine assembly and torque converter, transmission assembly
t t t t t t
1 1 1 1 1 1 2 Centring engine assembly and torque converter, transmission assembly Removal, installation of PTO nut Removal, installation of pump nut Disassembly, assembly of trque converter assembly
t t t t t
1 1 1 1 1
Checking actuation of piston
Disassembly, assembly of differential assembly
Adjust side bearing preload
30-5-1
(10)
HD465-7, HD605-7
SPECIAL TOOL LIST
Component
Symbol 3
Part No. 790-102-1130 797-101-1171 792T-422-1610
Part Name Power wrench Power wrench Spacer Bolt Washer Spring washer Installer Push tool Installer Push tool Push tool Push tool Grip Bolt Suspension tool Pump assembly Charging tool Pilot ring tool Tool installer set Repair stand Hydraulic pump Wrench Socket Push tool KIT Push tool KIT Grip Bolt Push tool KIT Push tool KIT Grip Bolt
Nature of work, remarks Removal, installation of bearing cap bolt Removal, installation of pinion bearing lock nut
Diffelential assembly
H 4
t t t t t t t t t t t t t t t
1 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 N
01010-61620 01643-31645
Final drive and rear brake, parking brake assembly
2 J 3
795-102-2102 792-520-2110 792-520-1600 791-585-1510
Removal, installation of spring Removal, installation of floatin seal (for small diameter) Removal, installation of floatin seal (for large diameter)
4 792-530-1700 792-103-4102 792-625-1300 1 790-101-5421 Suspension cylinder assembly Q 01010-81240 792-610-1000 2 792-610-1100 792-610-1200 1 Steerin valve assembly T 2 1 790-101-1102 2 3 790-102-3802 790-302-1270 790-201-1702 790-101-1771 Steering cylinder assembly U 4 790-101-5021 01010-50816 790-201-1500 790-101-1580 5 790-101-5021 01010-50816 790-452-1100 790-502-1003 790-452-1200
Press fitting of bushing (for front) (for rear)
Adjusting of suspension cylinder
t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1
Centering valve body and upper case Installation of spacer Disassembly and assembly steering cylinder Removal of cylinder head Removal of piston nut
Press fitting of bushing 1 1 1 1 Press fitting of dust seal 1 1
HD465-7, HD605-7
30-5-2
(10)
SPECIAL TOOL LIST
Component
Symbol 6
Part No. 790-720-1000 796-720-1650 07281-01029 790-502-1003
Part Name Expander Ring Clamp Repair stand Hydraulic pump Wrench Expander Ring Clamp Push tool Grip Bolt Push tool KIT Push tool Grip Bolt Plate Grip Bolt Push tool KIT Push tool Grip Bolt Hook Service KIT tool Vacuum pump Vacuum pump (220V) Vacuum pump (240V) Gas leak detector
Nature of work, remarks
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Charging of air conditioner gas Lifting of dump body Press fitting of dust seal (for cylinder ) Press fitting of dust seal (for cylinder ) Press fitting of bushing (for cylinder ) Press fitting of bushing (for cylinder ) Removal of piston ring Disassembly, assembly of hoist cylinder Removal, installation of cylinder dead Removal of steerig cylinder
Steering cylinder assembly U 7 8 1
790-101-1102 2 3 4 5 790-102-3802 790-720-1000 796-720-1680 07281-01580 792-201-7310 790-101-5421 01010-81240 6 Hoist cylinder assembly H 790-201-1851 790-101-5021 01010-50816 792-201-7410 790-101-5021 01010-80816 7 790-201-1500 790-201-1660 790-201-5021 01010-50816 Dump body assembly V1 790-441-1320 799-703-1200 799-703-1100 Air conditioner assembly X 799-703-1111 799-703-1121 799-703-1401 790-201-1702
30-5-3
(11)
HD465-7, HD605-7
SKETCH OF SPECIAL TOOL
SKETCH OF SPECIAL TOOL

J1 Spacer
HD465-7, HD605-7
30-5-4
(10)
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative () terminal of the battery. 1. Close the fuel supply valve. 2. Remove the clamp and move hose (1). 3. Disconnect wiring connector (2). 4. Disconnect fuel hose (3) and fuel tubes (4) and (5). 5. Remove mounting bolts (6) and fuel pump assembly (7).
INSTALLATION
Carry out installation in the reverse order to removal.
Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
30-6
HD465-7, HD605-7
RADIATOR
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative () terminal of the battery. 1. Remove the engine underguard. 2. Drain the coolant. Radiator: 69 3. Bleed air conditioner refrigerant gas. 4. Remove radiator mask (1) and guard (2). Mask : 30 kg Guard : 100 kg
6. Disconnect wiring connector (5) and hose (6) from the left side of the radiator and move hose (7).
7. Disconnect hose (8) from the left bottom of the radiator.
8. Remove tube (9). 9. Disconnect hose (10). 10. Remove hose (11) form the clamp and move it. 5. Disconnect hoses (3) and (4).
HD465-7, HD605-7
30-7
(10)
RADIATOR
11. Disconnect wiring connector (12) of the coolant level sensor above the radiator.
15. Remove air conditioner condenser (18), fuel cooler (19), steering oil cooler (20), and air aftercooler (21) from the radiator assembly.
12. Disconnect hoses (13) and (14) above the radiator and remove pipe (15). 13. Remove guard (16).
INSTALLATION
Charge the air conditioner circuit with refrigerant gas (R134a). , Hose clamp: 13.7 0.5 Nm {140 5 kgcm}
14. Lift off radiator assembly (17). Radiator assembly: 310 kg
a When using 2 hose clamps to the same place, set their clamps at an angle of 180 to each other. Refilling with coolant Add coolant through the filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69
30-8
(10)
HD465-7, HD605-7
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER
REMOVAL AND INSTALLATION OF ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER ASSEMBLY
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. 1. Remove the engine underguard. 2. Drain the engine oil and hydraulic oil. Engine oil pan: 57 Hydraulic tank: 122 3. Disconnect hose (1) from the underside of the cooling fan.
INSTALLATION
Mounting bolt: Adhesive (LT-2) 4. Disconnect hoses (2) and (3). 5. Remove tubes (4) and (5). 6. Supporting the engine and torque converter and transmission oil cooler assembly (6) with jacks, etc., remove them. Engine and torque converter and transmission oil cooler assembly: 140 kg Mounting bolt: 245 309 Nm {25 31.5 kgm} [Target: 279 Nm {28.5 kgm}] Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Engine oil pan: 57 (EO10-CD or EO30-CD) (EO10-CD)
Hydraulic tank: 122
HD465-7, HD605-7
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ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

Special tools
New/Remodel Symbol
INSTALLATION
1. Using tool A2, press fit engine front seal (3) and dust seal (2) together to the front cover. a Press fitting dimension a of dust seal: 4 mm
795-621-1140 A2 795-902-1460 01582-02218
Push tool Bolt Nut
t t t
1 3 3
REMOVAL
1. Remove the radiator assembly. For details, see REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY. 2. Remove the fan belt. 3. Remove crank pulley (1). Crank pulley: 55 kg 3. Carry out the rest of installation work in the reverse order to removal. 2. Install crank pulley (1). Mounting bolt: 1st time : 73.5 19.6 Nm {7.5 2 kgm} 2nd time : 245.0 19.6 Nm {25 2 kgm} 3rd time : 637.0 19.6 Nm {65 2 kgm}
4. Remove dust seal (2) and engine front seal (3).
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Sketch
Part No.
Part name
Necessity
Q'ty
HD465-7, HD605-7
OUTPUT SHAFT
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Remove drive shaft assembly (1). Drive shaft assembly: 30 kg 2. Remove coupling (2). 3. Remove cover (3).
INSTALLATION
Carry out installation in the reverse order to removal. a For application of ENS grease to each part, see DISASSEMBLY AND ASSEMBLY.
Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 123 Nm {10 12.5 kgm}
Mounting bolt: 98 123 Nm {10 12.5 kgm}
Mounting bolt: 98 123 Nm {10 12.5 kgm}
4. Remove snap ring (4). 5. Remove the bearing and cover (5) together. a Use the guide bolt and forcing screws to remove the bearing and cover. Cover assembly: 35 kg 6. Lift off output shaft assembly (6). Output shaft assembly: 90 kg
HD465-7, HD605-7
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OUTPUT SHAFT
DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
DISASSEMBLY
1. Oil cage assembly Remove oil seal (1) from cover (2). 2. Cover assembly Remove bearing (3) from cover (4). 3. Disassembly of damper assembly (5) 1) Before disassembling, make marks of flange (6), body assembly (7), and body outer (9) for balancing them for reassembly. 2) Remove body assembly (7) and rubber pieces (8) from body outer (9). a There are 2 rubber pieces (8), large one and small one. Check their locations. 3) Remove bearing (10) from the flywheel.
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HD465-7, HD605-7
OUTPUT SHAFT
ASSEMBLY
3. Install damper assembly (5) to the flywheel. Spline of body assembly shaft: ENS grease 4. Press fit bearing (3) to cover (4). Bearing: ENS grease 5. Install cover assembly to the flywheel. Cover assembly: 55 kg Mating faces of cover assembly and flywheel: Gasket sealant (LG-6) Mounting bolt: 98 123 Nm {10 12.5 kgm} 6. Fit oil seal (1) to cover (2). Insertion part of cover and outside of oil seal: LOCTITE 648 (287-01-12830) a Degrease and dry the above parts before applying gasket sealant. Mating faces of covers (2) and (4): Gasket sealant (LG-6) Mounting bolt: 98 123 Nm {10 12.5 kgm}
1. Using the push tool, press fit bearing (10) to the flywheel. Bore of bearing: ENS grease 2. Assembly of damper assembly 1) Apply gasket sealant to body outer (9) and the mating face of flange (6), then install them. Mating face of flange: Gasket sealant (LG-6) 2) Install body assembly (7). 3) Install body outer (9), body assembly (7), and rubber pieces (8). a When installing large and small rubber pieces (8), check their locations. a Before installing these parts, apply grease to them. Body outer, body assembly, and rubber pieces: Grease (G2-LI) Mounting bolt: 98 123 Nm {10 12.5 kgm} 4) Install flange (6). Mating face of flange: Gasket sealant (LG-6) Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 123 Nm {10 12.5 kgm} a When installing the body outer, body inner, and flange, match them to their marks.
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OUTPUT SHAFT
7. Install the cage assembly to the cover assembly. Procedure for filling ENS grease 1) Part No. of ENS grease: 427-12-11871 2) Parts to be filled with ENS grease, quantity of ENS grease to be supplied (Total: Approx. 500 g), and parts to be coated with ENS grease are shown below.
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HD465-7, HD605-7
ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

Special tools
New/Remodel Symbol
INSTALLATION
1. Using tool A3, press fit engine rear seal (2) until it comes to the end of the housing.
A3
795-621-1130 01050-32280
Push tool Bolt
t t
1 5
REMOVAL
1. Remove the output shaft assembly. For details, see REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY. 2. Install guide bolt [1] and lift off flywheel (1). Since the faucet joint part of the flywheel is shallow, the flywheel may fall suddenly. Take care. Flywheel: 45 kg
Sketch
Part No.
Part name
Necessity
Q'ty
2. Install flywheel (1). a Secure the flywheel and housing with a stopper, etc. a Check each mounting bolt head for punch marks. If there are 5 punch marks, replace the bolt. a Tighten the mounting bolts to the specified torque in the following order. Mounting bolt: Engine oil (EO30-CD) Mounting bolt: 1st time : 198 19.6 Nm {20 2 kgm} 2nd time : 460.6 19.6 Nm {47 2 kgm} 3rd time : 90 +30 0 a When reusing a bolt, make a punch mark on its head after tightening it.
3. Remove engine rear seal (2).
HD465-7, HD605-7
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ENGINE REAR SEAL
a Using dial gauge [2], check the flywheel for radial runout and facial runout. Radial runout: Max. 0.15 mm Facial runout: Max. 0.20 mm
3. Carry out the rest of installation work in the reverse order to removal.
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HD465-7, HD605-7
CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

Special tools
New/Remodel Symbol Necessity
9. Loosen the hose clamp and remove air intake connector (9).
795-799-5410 795-799-5420
Adapter Remover
t t
1 1
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative () terminal of the battery. 1. Drain the coolant. Radiator: 69 2. Open the engine top cover and remove the battery case in the rear and engine cover. 3. Remove fuel filter bracket assembly (1). 4. Disconnect fuel tubes (2) and (3). 5. Remove corrosion resistor and bracket assembly (4). 6. Disconnect each wiring connector and ground wire and move wiring harness (4). 7. Remove air intake connectors (6) and (7). 8. Remove air intake manifold (8). Reference: The same parts are used in the front and rear sections. 14. Remove turbocharger and exhaust manifold assembly (16). Turbocharger and exhaust manifold assembly: 60 kg 10. Remove air intake tube (10). 11. Remove covers (11) and (12). 12. Disconnect lubrication tubes (13) and (14). 13. Disconnect exhaust tube (15).
Sketch
Part No.
Part name
Q'ty
HD465-7, HD605-7
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CYLINDER HEAD
15. Remove spill tube (30). 16. Remove cylinder head cover (32).
20. Remove the mounting bolts and rocker arm housing (37).
17. Remove rocker arm assembly (33). Loosen the locknut, then loosen adjustment screw 2 3 turns.
21. Remove cylinder head mounting bolts (38). Using the sling bolts, remove cylinder head assembly (39). Cylinder head assembly: 60 kg
18. Remove cross heads (34) and push rods (35).
19. Using tool A, remove injector assembly (36).
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HD465-7, HD605-7
CYLINDER HEAD
INSTALLATION
Carry out installation in the reverse order to removal. Mounting bolt of cylinder head cover: 9.8 1.0 Nm {1 0.1 kgm}
Fuel tube sleeve nut (2): 43 47 Nm {4.4 4.8 kgm} Fuel tube sleeve nut (3): 24 27 Nm {2.4 2.8 kgm}
Clean the mounting bolt holes before installing the bolts. Check that the ball of the adjustment screw is fitted to the socket of the push rod. Rocker arm mounting bolt: Engine oil (EO30-CD) Rocker arm mounting bolt: 235.2 254.8 Nm {24 26 kgm} Locknut: 57.8 77.4 Nm {5.9 7.9 kgm}
Tighten the mounting bolts of the air intake manifold in the following order.
Adjust each cross head according to the following procedure. 1) Loosen the locknut and return the adjustment screw until it does not touch the valve stem. 2) Hold the contact face of the cross head against the rocker arm and keep the cross head in contact with the valve stem on the push rod side. 3) Tighten the adjustment screw gradually. After it touches the valve stem, tighten it 20 30 further. 4) Tighten the locknut. Locknut: 53.0 64.7 Nm {5.4 6.6 kgm}
Tighten the mounting bolts of the turbocharger and exhaust manifold in the following order. Mounting bolt of turbocharger and exhaust manifold assembly: 1st time : 39.2 58.8 Nm {4 6 kgm} 2nd time : 112.8 122.5 Nm {11.5 12.5 kgm}
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CYLINDER HEAD
1) Using tool A, insert injector (60) in the cylinder head. O-ring: Engine oil (EO30-CD) When inserting the injector, check that the gasket at its end will not fall. Direct the draft hole of the injector toward the diagonal point of the holder and set the holder to the installation position, too. Insert the injector straight in the cylinder head hole. Using the cylinder side of tool A, press the injector top and set the seal of its end to the cylinder head.
Rocker arm housing: Gasket sealant (LG-7) Apply the gasket sealant in a line 2 3 mm in diameter along the housing groove as shown below. Mounting bolt: 78.4 93.2 Nm {8.0 9.5 kgm}
2) Tighten the holder mounting bolts. Measure stem length a of each mounting bolt. If it is 80 mm or longer, do not use the bolt but use new one. Threads and seat of mounting bolt: Engine oil (EO30-CD) Mounting bolt: 1st time: 24.5 34.3 Nm {2.5 3.5 kgm} 2nd time: Retighten 90 +30 0
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HD465-7, HD605-7
CYLINDER HEAD
a Check that there is not foreign matter on the fitting face of the cylinder head and in the cylinder. a When fitting the gasket, check that the grommet is not removed. a Check each mounting bolt head for punch marks. If there are 3 punch marks, replace the bolt. a Tighten the cylinder head mounting bolts in the following order. Mounting bolt: Molybdenum disulfide grease (LM-P) Cylinder head mounting bolts ((1) (7)): 1st time : 245 9.8 Nm {25 1 kgm} 2nd time : 382.5 9.8 Nm {39 1 kgm} 3rd time : Make marks on bolts and cylinder head with paint, then retighten the bolts 90 120. Mounting bolts ((8), (9)) 93.2 103 Nm {9.5 10.5 kgm}
a After tightening the bolts, make a punch a mark a on the main bolt (Do not make the punch mark if the bolts are new).
Refilling with coolant Add coolant through the filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69
HD465-7, HD605-7
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ENGINE
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

Special tools
5. Disconnect exhaust tube (5). 6. Disconnect wiring connector E13A (6) and E13B (7).
792-420-1110 C4 792-420-1120 790-413-1120 01010-51230
Centering tool Flange Collar Bolt
1 2 1 8
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative () terminal of the battery. 1. Remove battery box (1), engine top cover (2) (2A), air cleaner (3), and air intake tube. 7. Remove engine oil cooler tubes (8) and (9).
Sketch
Part No.
Part name
Q'ty
8. Disconnect wiring connectors SIG (10), POW (11), and ENG (12) from the left rear part of the engine and remove bracket (13). 9. Disconnect hoses (15) and (16).
2. Remove the radiator assembly. For details, see REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY. 3. Remove the radiator cross bar. 4. Remove washer tank (4).
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HD465-7, HD605-7
ENGINE
10. Remove oil filter bracket assembly (17). 11. Disconnect hoses (18) and (19). 12. Disconnect air conditioner pipe (20).
13. Remove plate (21) and drive shaft (22). Drive shaft: 30 kg
14. Sling the engine assembly temporarily. 15. Remove engine mounting bolts (23) and (24) and pull out engine assembly (25) forward to remove it. a When removing the engine assembly, check that the all wires and pipes are disconnected and take care that the engine assembly will not interfere with the chassis. Engine assembly: 2,750 kg
HD465-7, HD605-7
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ENGINE
INSTALLATION
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69
a When tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke. Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 123 Nm {10 12.5 kgm}
a Center the engine assembly and torque converter and transmission assembly according to the following procedure. 1. Install flange (C4-1) and collar (C4-2) of tool C4 between coupling (20) on the engine side and coupling (21) on the torque converter side. 2. Center the engine assembly and torque converter and transmission assembly by moving the engine assembly so that collar (C4-2) will move smoothly between both flanges while coupling (21) on the torque converter side makes a full turn. Reference: The allowable vertical and lateral deviation between both flanges is 3 mm maximum.
Engine mount mounting bolt (Both front and rear): 343 426.3 Nm {35.0 43.5 kgm} a If the engine mount bracket was removed from the chassis, tighten its mounting bolts to the following torque. Mounting bolt of front engine mount bracket: 343 426.3 Nm {35.0 43.5 kgm} Mounting bolt of rear engine mount bracket: 450 608 Nm {50 62 kgm}
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HD465-7, HD605-7
TORQUE CONVERTER AND TRANSMISSION
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY

Special tools
New/Remodel Symbol
6. Disconnect hose (4) and tube (5).
792-420-1110 C4 792-420-1120 790-413-1120 01010-51230
Centering tool Flange Collar Bolt
1 2 1 8
Sketch
Part No.
Part name
Necessity
Q'ty
7. Remove drive shaft (6). Drive shaft: 30 kg 8. Disconnect hoses (7), (8), (9), (10), and (11).
REMOVAl
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative () terminal of the battery. 1. Remove the transmission underguard. 2. Drain the transmission oil and hydraulic oil. Transmission case: 190 Hydraulic tank: 122 3. Disconnect wiring connectors (1) (TM2 and TM3). 4. Remove drive shaft (2). Drive shaft: 65 kg 5. Disconnect hose (3).
HD465-7, HD605-7
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(3)
9. Disconnect hoses (12), (13), and (14) and tubes (15) and (16) from the left underside of the transmission.
11. Remove mounting bolts (17) and (18) of the front and rear mounts, then remove torque converter and transmission assembly (19). a When removing the torque converter and transmission assembly, check that the all wires and pipes are disconnected and take care that the assembly will not interfere with the chassis. a Check the thickness and quantity of the shims set in the rear mount. Standard thickness of shims: 2 mm Thickness of each shim: 0.5 mm (1 type) Torque converter and transmission assembly: 1,600 kg
10. Sling the torque converter and transmission assembly temporarily.
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HD465-7, HD605-7
INSTALLATION
Carry out installation in the reverse order to removal. , a When tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke.
a If the transmission mount bracket was removed from the chassis, tighten its mounting bolts to the following torque. Mounting bolt: 450 608 Nm {50 62 kgm} Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190 (EO30-CD or EO10W-CD) (EO10-CD)
Mounting bolt: Adhesive (LT-2) Mounting bolt: 157 198 Nm {16.0 20.1 kgm}
Hydraulic tank: 122
a Center the engine assembly and torque converter and transmission assembly according to the following procedure. 1. Install flange (C4-1) and collar (C4-2) of tool C4 between coupling (20) on the engine side and coupling (21) on the torque converter side. 2. Center the engine assembly and torque converter and transmission assembly by moving the engine assembly so that collar (C4-2) will move smoothly between both flanges while coupling (21) on the torque converter side makes a full turn. Reference: The allowable vertical and lateral deviation between both flanges is 3 mm maximum.
HD465-7, HD605-7
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TRANSMISSION AND TORQUE CONVERTER
SEPARATION AND COUPLING OF TRANSMISSION ASSEMBLY AND TORQUE CONVERTER ASSEMBLY

SEPARATION
1. Remove pump assemblies (1), (2), and (3) and their pipes. Retarder cooling pump assembly (1): 30 kg Steering hoist and hoist control pump assembly (2): 35 kg Torque converter, transmission, retarder cooling, and brake pump assembly (3): 25 kg 2. Remove plate (4) and trunnion (5). 3. Remove cover (6) and disconnect torque converter oil temperature sensor connector (7) and torque converter intermediate oil pressure sensor connector (8).
5. Lift off torque converter assembly (9). Torque converter assembly: 410 kg 6. Remove seal rings (10) and (11).
COUPLING
Carry out coupling in the reverse order to separation.
Torque converter assembly mounting bolt: 245 308.7 Nm {25 31.5 kgm}
Outside of seal ring: Grease (G2-LI)
4. Sling the torque converter and transmission assembly, then place it with the torque converter side up.
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HD465-7, HD605-7
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY

Special tools
New/Remodel Symbol
790-501-5000 1 C 2 3 790-901-2110 790-901-3011 790-101-1871 792-103-5110
Unit repair stand Bracket Plate Nut wrench Wrench
1 1 1 1 1
Sketch
Part No.
Part name
Necessity
Q'ty
DISASSEMBLY
1. Set the torque converter assembly to tool C1. 2. Remove control valve assembly (1). 3. Remove torque converter oil temperature sensor (2) and torque converter intermediate oil pressure sensor (3). 4. Remove elbows (4) and (5) and tube (6).
2) Using 2 forcing screws [1], lift off PTO case assembly (10). Before removing the PTO case assembly, make match marks on it.
6. Disassembly of PTO case assembly 1) Using tool C2, remove nuts (9). 2) Remove snap ring (12) and plate (13).
5. PTO case assembly 1) Remove holder (7) and coupling (8). Before removing the holder and coupling, loosen 3 nuts (9) with tool C2 (Use the coupling as a stopper).
HD465-7, HD605-7
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TORQUE CONVERTER
3) Press the shaft to remove PTO gear and bearing assembly (14). If the PTO gear and bearing assembly comes off, bearing (15) comes off, too. 4) Remove inner race spacer (16) and bearing (17) from the PTO gear. 5) Remove outer races (18) and (19) and outer race spacer (20) from the PTO case. Since parts (15) (20) form an assembly, do not replace any of them with one of another assembly. (The combination symbol is stamped on each part.)
9) Remove bushing (25) and outer race (26) from the PTO case.
7. Turbine and clutch assembly 1) Remove mounting bolts (27) on the pump side. 2) Remove turbine and clutch assembly (28).
6) Remove snap ring (21). 7) Using forcing screws [2], remove cage (22).
8. Disassembly of turbine and clutch assembly 1) Input shaft i) Using forcing screws [3], remove input shaft (29). ii) Remove bearing (30) from the input shaft. 8) Remove oil seal (23) and dust seal (24) from the cage.
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HD465-7, HD605-7
TORQUE CONVERTER
2) Turn over the drive case and remove the mounting bolts and turbine (31).
6) Using push tool [4], remove shaft (38) from clutch housing assembly (33), then remove piston (39).
3) Remove drive case (32) from clutch housing assembly (33). 4) Remove 2 discs (34) and plate (35).
7) Remove seal rings (40) from piston (39).
5) Turn over the clutch housing and remove snap ring (36) and plate (37).
8) Using push tool [5], remove bearing (41) from the clutch housing. 9) Remove pin (42) and seal ring (43).
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TORQUE CONVERTER
9. Stator assembly Pull up and remove stator assembly (44).
11. Disassembly of pump, stator shaft, and rear housing assembly 1) Remove snap ring (51) and inner race (52). 2) Using tool C3, remove nuts (53).
10. Disassembly of stator assembly 1) Remove stator (45). 3) Remove the pump, stator shaft, and rear housing assembly from tool C1. 4) Remove the mounting bolts and push out and remove stator shaft (54). a At this time, inner race (55) comes off.
2) Remove bushings (47) and (48) and free wheel (49) from outer race (46). a Take care not to lose balls (50).
5) Remove seal ring (56), inner race (57), and sleeve (58) from stator shaft (54).
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HD465-7, HD605-7
TORQUE CONVERTER
6) Remove retainer (60) and guide (61) from pump (59). 7) Remove bearing (62) from guide (61).
ASSEMBLY
1. Assembly of pump, stator shaft and rear housing assembly 1) Install bearing (62) to guide (61) and install them to pump (59). a Bearing (62) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating inner race. 2) Install retainer (60) to pump (59). Retainer mounting bolt: Adhesive (LT-2) Retainer mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
3) Press fit inner race (57) to stator shaft (54). a Inner race (57) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating bearing. 4) Fit sleeve (58) and seal ring (57). a Fit sleeve (58) by expansion fit. Outside of seal ring: Grease (G2-LI)
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(3)
TORQUE CONVERTER
5) Install stator shaft assembly (54) to rear housing (63). Mounting bolt: Adhesive (LT-2) Mounting bolt: 98.1 122.6 Nm {10 12.5 kgm}
8) Using tool C3, tighten nuts (53). a Drop about 6 CC of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns. Threads of nut: Adhesive (LT-2) Nut: 441.3 490.3 Nm {45 50 kgm} 9) Install inner race (52) and snap ring (51). a Install the inner race with the wider end face up.
6) Install the stator shaft and rear housing assembly to tool C1. 7) Install pump assembly (64) and inner race (55) to stator shaft (54). a Inner race (55) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating bearing.
2. Assembly of stator assembly 1) Install free wheel (49) to outer race (46). a Install the free wheel with its arrow mark end on the input side. Check the revolving direction of the outer race, seeing it from the input side. Clockwise: Free rotation Counterclockwise: Locked Sliding surface: Engine oil (EO10-CD or EO30-CD) 2) Install balls (50) to outer race (46), then install bushings (48) and (47) by expansion fit. Sliding surface: Engine oil (EO10-CD or EO30-CD)
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HD465-7, HD605-7
TORQUE CONVERTER
3) Install stator (45). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
3) Using push tool [6], install bearing (41) to the clutch housing. Press fit the bearing until it is stopped by the clutch housing. Drop about 6 cc of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns.
3. Stator assembly Install stator assembly (44). 4) Install seal ring (40) to piston (39). For the installing direction, see the following figure. Outside of seal ring: Grease (G2-LI)
4. Assembly of turbine and clutch assembly 1) Install seal ring (43) to the clutch housing. For the installing direction, see the following figure. Outside of seal ring: Grease (G2-LI) 2) Install pin (42) by expansion fit.
5) Install piston (39) to clutch housing assembly (33). 6) Using push tool [7], press fit shaft (38) to clutch housing assembly (33). Press fit the shaft until it is stopped by the bearing.
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TORQUE CONVERTER
7) Install plate (37) to the shaft, then install snap ring (36).
8) Install 2 discs (34) and plate (35). Sliding surface of disc: Engine oil (EO10-CD or EO30-CD) 9) Install drive case (32) to clutch housing assembly (33). Watch through holes A (at 6 places on the periphery) and check that plate (35) is meshed with the gear of drive case (32). Mounting bolt: Adhesive (LT-2) Mounting bolt: 98.1 122.6 Nm {10 12.5 kgm}
11) Input shaft i) Using push tool [8], install bearing (30). Drop about 6 cc of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns. ii) Install input shaft assembly (29) to clutch housing assembly (33). Mounting bolt: Adhesive (LT-2) Mounting bolt: 269.7 308.9 Nm {27.5 31.5 kgm}
10) Install turbine (31). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
5. Turbine and clutch assembly 1) Install turbine and clutch assembly (28). 2) Tighten mounting bolts (27) (30 pieces). Mounting bolt: Adhesive (LT-2) Mounting bolt: 49.0 58.8 Nm {5 6 kgm}
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HD465-7, HD605-7
TORQUE CONVERTER
6. Assembly of PTO case assembly 1) Press fit outer race (26) and bushing (25) to the PTO case. After press fitting bushing (25), bend the PTO case end (by 4 points equally spaced on the periphery) with a punch, etc. until it is over the bushing.
3) Fit the O-ring to cage (22) and install them to the PTO case. 4) Install snap ring (21). Install the snap ring so that its closed gap will be on the left side (in the direction of 9 o'clock) when it is on the truck and seen from the engine side.
2) Using push tool [9], install dust seal (24) and oil seal (23) to cage (22). i) Thinly apply gasket sealant (LG-5) to the seal fitting surface inside the cage.ii) ii) Install the seals so that the distances from the cage top to their tops will be as follows. Distance a: 23.6 0.2 mm Distance b: 8.75 0.25 mm After installing, wipe off the projected gasket sealant thoroughly. iii) Fill the space between the oil seal and dust seal and the space between the lips of the oil seal with silicone grease (ThreeBond 1855) Supply grease of quantity equivalent to 40 60% of the space between the lips so that it will not be projected.
5) Install outer race spacer (20) and outer races (18) and (19) to the PTO case. 6) Install bearing (17) and inner race spacer (16) to the PTO gear. 7) Install PTO gear and bearing assembly (14) to the PTO case, then install bearing (15) to the shaft. Since parts (20) (15) form an assembly, do not replace any of them with one of another assembly. (The combination symbol is stamped on each part.) Apply grease (G2-LI) to the inside spline of the PTO gear shaft.
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TORQUE CONVERTER
8) Install plate (13) and snap ring (12). 9) Using tool C2, tighten nuts (9) temporarily. a Install the nuts with the chamfered side down. a Tighten the nuts fully after installing the PTO case assembly. After this, follow the procedure: 7-3 (making coupling serve as a stopper). Threads of nut: Adhesive (LT-2)
8. Install elbows (5) and tube (6). a When installing elbows (5), check that there are stamps of <2> on their outside. Elbow: 34.3 63.8 Nm {3.5 6.5 kgm} 9. Install elbows (4). Threads of elbow: Gasket sealant (LG-5) Elbow: 16.7 29.4 Nm {1.7 3.0 kgm} 10. Install torque converter intermediate pressure sensor (3). Threads of sensor: Gasket sealant (LG-5) Sensor: 9.8 19.6 Nm {1 2 kgm} 11. Install torque converter oil temperature sensor (2). Threads of sensor: Gasket sealant (LG-5) Sensor: 29.4 49.0 Nm {3.0 5.0 kgm} 12. Install control valve assembly (1). Mounting bolt: 44.1 53.9 Nm {4.5 5.5 Kgm}
7. PTO case assembly 1) Sling PTO case assembly (10) and fit the Oring. Using guide bolt [10], install the PTO case assembly. a When installing the PTO case assembly, match the match marks. Mounting bolt: 98.1 122.6 Nm {10 12.5 kgm}
2) Install coupling (8) and holder (7). Mounting bolt: Adhesive (LT-2) Mounting bolt: 245.2 308.9 Nm {25 31.5 kgm} 3) Using tool C2, tighten the nuts (9) to the following torque which were tightened temporarily in steps 6-9). a Use the coupling as a stopper. Nut: 392.4 441.5 Nm {40 45 kgm}
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TRANSMISSION
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY

Special tools
New/Remodel Symbol
4) Remove cover (7) and lubricating oil temperature sensor (8). 5) Remove block (9).
D1
799-301-1600
Oil leak tester kit
DISASSEMBLY
1. Transmission mount, cover, wiring harness, and sensors 1) Remove both transmission mounts (1). 2) Remove covers (2) and (3). 2. Control valve assembly 1) Separate the connector of each control valve and remove wiring harness (10). 2) Install a sling bolt to position A and remove control valve assembly (11) and valve seat together. a After removing the control valve, cover the oil holes on the mating face of the transmission case with tapes, etc. to prevent foreign matter from entering the transmission case. 3) Remove each control valve (12) and filter assembly (13) from the valve seat.
3) Remove input shaft speed sensor (4), intermediate shaft speed sensor (5), and output shaft speed sensor (6).
Sketch
Part No.
Part name
Necessity
Q'ty
3. Sleeve Using a forcing screw, remove 5 sleeves (14).
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4. Oil pan 1) Sling transmission assembly (15) and remove oil pan (16).
5. Check of operation of pistons Using tool D1, blow air into the clutch ports and check the operation of the pistons of No. 1, 2, and 3 clutches. (Since you cannot check the operation of the pistons of No. 2 and 3 clutches directly, check it by movement of the discs or plates.) a The locations of the clutch ports are shown below. No. 1 clutch port: A No. 2 clutch port: B No. 3 clutch port: C a Air pressure: 0.29 0.59 MPa {3 6 kg/cm2} Standard stroke of clutch No. 1 piston: 4.2 mm
2) Remove cover (17) from the oil pan, then remove spring (18) and magnet assembly (19).
6. No. 1 clutch plates 1) Using sling bolts, remove No. 1 clutch plates (24). a There are 2 bolts installed from the transmission case side. 3) Remove blocks (20) and (21) from the oil pan, then remove relief valves (22) and (23).
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2) Remove bearing (25) from No. 1 clutch plates.
2) Remove seal rings (100) and (101) from piston (32).
7. No. 1 clutch spring and guide Remove spring (26) and guide (27). 8. Discs, plates, and springs Remove discs (28), plates (29), and spring (30).
10. Input shaft and No. 1 ring gear assembly 1) Sling the input shaft and remove the input shaft and No. 1 ring gear assembly (33).
9. No. 1 clutch drum and piston 1) Using hanging bolts, remove clutch No. drum (31) and piston (32) together, then separate them from each other.
2) Pull up and remove No. 1 ring gear (34). 3) Remove seal rings (206) and (207) from the input shaft.
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TRANSMISSION
4) Remove inner race (35) from No. 1 ring gear (34).
7) Remove snap ring (39), then remove bearing (40) from input shaft (41).
5) Remove snap ring (36) and press down and remove gear (37).
11. No. 2 clutch assembly Lift off No. 2 clutch assembly (42).
6) Remove inner race (38) from gear (37).
12. Disassembly of No. 2 clutch assembly 1) Turn over No. 2 clutch assembly and remove housing (43).
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2) Remove mounting bolts, cover (44), and piston (45).
5) Remove snap ring (53) and ring gear (54).
3) Remove seal ring (46) from piston (45).
6) Remove discs (55), plates (56), and spring (57). 7) Using sling bolts, remove drum (58).
4) Housing assembly i) Remove seal rings (47) and (48). ii) Remove snap ring (49), bushing (50), and ball (205). aTake care not to lose ball (205). iii) Remove inner race (51) and bearing (52).
8) Remove plates (59) from carrier (60).
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TRANSMISSION
9) Carrier assembly i) Remove shaft (61). a Take care not to lose ball (62). ii) Remove planetary gears (63), thrust washer (64), and bearing (65).
13. Transmission case 1) Remove cage assembly mounting bolts (69) and lift off transmission case (70) vertically.
2) Remove the following parts from the transmission case. i) Remove the assembly of cage (71) and bearings (72), then remove the bearings from the cage. ii) Remove collars (73) and bearings (74) from the case. iii) Remove seal ring (204) from the collar.
iii) Remove seal ring (66), inner race (67), and bearing (68) from carrier (60).
14. Check of operation of piston Using tool D1, check the operation of pistons of No. 4, 5, 6, and 7 clutches. a Air pressure: 0.29 0.59 MPa {3 6 kg/cm2} Standard strokes of pistons
Piston No. 4 5 6 7 Stroke (mm) 4.8 5.8 5.0 5.0
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17. No. 3 clutch ring gear 1) Remove No. 3 clutch ring gear (80). 2) Remove inner race (81) and seal ring (82) from the ring gear.
15. No. 3 clutch housing assembly Remove the housing mounting bolts and No. 3 clutch housing assembly (75). a For disassembly, see Step 12, DISASSEMBLY OF NO. 2 CLUTCH ASSEMBLY, 1) - 4). (No. 3 clutch assembly has the same structure as No. 2 clutch assembly.)
18. Tie bolts Remove tie bolts (83). 16. No. 3 clutch drum, discs, and plates 1) Using hanging bolts, remove No. 3 clutch drum (76), discs, plates, and spring together. 2) Remove discs (77), plates (78), and spring (79). 19. No. 4 clutch plates and sun gear 1) Remove plates (84). 2) Remove snap ring (85) and sun gear (86).
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3) Remove seal ring (200) from No. 4 sun gear (86).
21. No. 4 housing, piston, and ring gear 1) Using hanging bolts, remove No. 4 housing (91), piston (92), and ring gear (93) together. a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage.
20. No. 4 clutch discs, plates, and springs Remove discs (87), plates (88) and (101), and springs (89) and (90). a Distinguish plates (88) and (101) from each other. a Since springs (90) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.
2) Remove seal rings (93) and (94) from No. 4 housing (91) and piston (92).
22. No. 5 clutch discs, plates, and springs Remove discs (95), plates (96), and springs (97) and (98). a Since springs (97) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.
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4) Remove sleeve (203) for tie bolt (83) from No. 5 housing and check the direction of the sleeve (slit A).
23. No. 5 housing, piston, ring gear, and guide pins 1) Using sling bolts, remove No. 5 housing (99), piston (102), and ring gear (103) together. a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage. 2) Remove guide pins (202).
24. No. 6 clutch discs, plates, and springs Remove discs (108), 4 plates (109) and (110), and springs (111) and (112). a Since springs (111) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line. a Distinguish plates (109) and (110) from each other.
3) Remove seal rings (106) and (107) from No. 5 housing (99) and piston (102).
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TRANSMISSION
25. No. 4 and No. 5 carriers assembly Using hanging bolts, remove No. 4 and No. 5 carriers assembly (201).
4) Drive out shaft (117) from the ball side and remove No. 5 planetary gears (119), bearing (120), collar (121), and thrust washer (122). a At this time, 4 of 8 No. 5 planetary gears come off.
26. Disassembly of No. 4 and No. 5 carriers assembly 1) Remove No. 5 sun gear (113).
5) Drive out shaft (123) toward No. 4 carrier and remove ball (124). a Take care not to lose ball (124). 6) Drive out shaft (123) further and remove it. 7) Remove No. 4 planetary gears (300), bearing (125), thrust washer (126), No. 5 planetary gear (119), bearing (120), collar (121), and thrust washer (122). 8) Remove snap ring (127) and ring gear (129).
2) Turn over the carrier assembly and remove bearing (115) and seal ring (116).
3) Drive out shaft (117) toward the ball and remove ball (118). a Take care not to lose the ball.
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27. No. 6 and No. 7 housings, pistons, and springs 1) Using sling bolts, remove No. 6 and No. 7 housings (131) and pistons (132) and (133). a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage.
29. No. 6 and No. 7 carriers assembly Using sling bolts, sling the shaft and remove No. 6 and No. 7 carriers assembly (142). 2) Remove seal rings (134), (135), and (136) from No. 6 and No. 7 housings and pistons (132) and (133).
30. Disassembly of No. 6 and No. 7 carriers assembly 1) Remove collar (143). 2) Remove inner race (144) and snap ring (145) from collar (143). 28. No. 7 clutch discs, plates, and springs Remove discs (138), plates (139), and springs (140) and (141). a Since springs (141) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.
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DISASSEMBLY AND ASSEMBLY 3) Tighten forcing screws [1] to remove plates (146). 4) Remove seal ring (147) and bearing (148) from the plates.
TRANSMISSION a Hit both shafts evenly to drive out the above parts gradually. 9) Remove seal ring (170) from collar (159). 10) Remove planetary gear No. 7 (162), bearing (163), and thrust washer (164). 11) Remove snap ring (165), collar (166), and ball (167). a Take care not to lose ball (167).
5) Remove intermediate shaft (149) and No. 6 sun gear (150) together. 6) Remove snap ring (151) and inner race (152) from intermediate shaft (149).
31. Guide pins and No. 7 clutch ring gear 1) Remove guide pins (168). 2) Remove No. 7 clutch ring gear (169).
7) Pull out shaft (153) and remove No. 6 planetary gear (154), bearing (155), thrust washer (156), and ball (157). a Take care not to lose ball (157). 32. Cage assembly 1) Using forcing screws [3], remove cover (172) from cage assembly (171). 2) Remove seal ring (173) from the cover. 3) Remove bearing (174) from the cage.
8) After removing No. 6 planetary gear, drive out shaft (158), collar (159), inner race (160), and ball (161), using drive shafts [2] (14 mm or less in diameter and about 200 mm in length). a Take care not to lose ball (161).
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33. Output shaft and cage assembly 1) Remove mounting bolts (301) and output shaft and cage assembly (175). Since the whole transmission is being disassembled now, the output shaft and cage assembly are removed at this time. You can remove only the output shaft assembly for repair of a leaking oil seal, etc., however, if you remove the speedometer gear (optional) in advance.
3) Support cage (178) and press the output shaft (179) with a press to drive it out of the bearing.
4) Remove bearing (180) from output shaft (179).
2) Remove worm (176) and collar (177) from the output shaft. The collar consists of 2 semicircular pieces.
5) Remove oil seal (181) and bearing (182) from cage (178).
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TRANSMISSION
ASSEMBLY
Clean the all parts and check them for dirt or damage before installing. Coat the sliding surfaces of each part with engine oil before installing. Soak the discs in clean engine oil (EO-10CD) for at least 2 minutes. Install each piston seal ring (a) of the clutch assembly with its pressure receiving side (side b) directed toward housing (c). Apply grease (G2-LI) to the periphery of the all seal rings. When fitting a bearing by expansion fit, drop engine oil (EO10-CD or EO30-CD) over it and rotate it 10 turns before chilling it in dry ice, etc.
1. Output shaft and cage assembly 1) Install bearing (182) and oil seal (181) to cage (178). Oil seal lip: Silicone grease (ThreeBond 1855) Press fitting surface on cage side: Gasket sealant (LG-5) After press fitting, wipe off the excessive gasket sealant.
2) Press fit bearing (180) to output shaft (179).
Securely fit springs (A) of No. 4 No. 7clutches to the seats of the piston and housing.
3) Set output shaft (179) on the press stand and press the inner race side of the bearing to install cage (178).
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TRANSMISSION
4) Install collar (177) and worm (176) to the output shaft. The collar consists of 2 semicircular pieces.
3. Guide pins and No. 7 clutch ring gear 1) Install guide pins (168) to the cage. 2) Install No. 7 clutch ring gear (169).
5) Fit the O-ring to the cage and install output shaft and cage assembly (175).
4. No. 7 clutch discs, plates, and springs Install discs (138), plates (139), and springs (140) and (141). Install the 4 discs and 3 plates. Securely fit springs (141) to the seats of the housing.
2. Cage assembly 1) Using the push tool, press fit bearing (174) to cage (171). 2) Install cover (172) to cage (171). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm} 3) Install seal ring (173) to cover (172). Periphery of seal ring: Grease (G2-LI)
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TRANSMISSION
5. No. 7 clutch piston Install seal ring (134) to piston (133), then matching it to the springs. Install the seal ring as shown below. Periphery of seal ring: Grease (G2-LI) 6. No. 6 and No. 7 housings and No. 6 piston 1) Install seal rings (134), (135), and (136) to housing (131) and piston (132). Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)
7. Assembly of No. 6 and No. 7 carriers assembly 1) Install bearing (163) to No. 7 planetary gear (162). Fit thrust washers (164) to both sides of them and set them to the carrier. 2) Press fit shaft (158) and set ball (161) to secure the shaft. When press fitting the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. 3) Install seal ring (170) to collar (159) and press fit inner race (160). Periphery of seal ring: Grease (G2-LI) 4) Install ball (167) and collar (166) to the carrier and secure them with snap ring (165). 5) Check that No. 7 planetary gear rotates smoothly.
2) Using sling bolts, sling No. 6 and No. 7 housings (131), matching them to piston (133). If the dowel pin is hard, drive it with a plastic hammer.
6) Install bearing (155) to No. 6 planetary gear (154). Fit thrust washers (156) to both sides of them and set them to the carrier. 7) Drive shaft (153) and set ball (157) to secure the shaft. When driving the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. 8) Check that No. 6 planetary gear rotates smoothly.
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9) Press fit inner race (152) to intermediate shaft (149). 10) Install snap ring (151). a Check that the snap ring is fitted to the groove. 11) Install No. 6 and No. 7 carrier intermediate shaft (149) and sun gear (150).
15) Install snap ring (145) to collar (143). a Check that the snap ring is fitted to the collar groove. 16) Press fit inner race (116) to collar (115) and install them to the intermediate shaft.
12) Press fit bearing (148) to plate (146). a Securely press fit the bearing to the specified stopper position. 13) Install seal ring (147). Periphery of seal ring: Grease (G2-LI) 14) Install plate (146) to No. 6 and No. 7 carriers. Mounting bolts: Adhesive (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
8. No. 6 and No. 7 carriers assembly Using sling bolts, sling the shaft. Install No. 6 and No. 7 carriers assembly (142), matching the gear to the bearing.
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9. Assembly of No. 4 and No. 5 carriers assembly 1) Install bearing (125) to No. 4 planetary gear (300). Fit thrust washers (126) to both sides of them and set them to the carrier. 2) Set collar (121) between 2 bearings (120) and install them to No. 5 planetary gear (119). Fit thrust washers (122) to both sides of them and set them to the carrier. 3) Chill shaft (123) in dry ice, then install it to the carrier. a Check that the shaft, bearing, thrust washers, and carrier are aligned and take care that the bearing and thrust washers will not be damaged. a Match the ball fitting hole of the shaft to the hole of the carrier. 4) Fit ball (124) and install shaft (123) securely. 5) Check that the gear rotates smoothly. 6) Install ring gear (129) to the carrier and secure it with snap ring (127). a Mesh the external teeth on the carrier side with the internal teeth on the ring gear side, then align the carrier with the ring gear so that the snap ring will be inside the 45 chamfering diameter of the ring gear. a Check that the external teeth are meshed with the internal teeth and the whole snap ring is inside the chamfering diameter of the ring gear, then press in the ring gear until it is locked. a Check that the clearance between the bottom of the external teeth of the carrier and the inside diameter of the fitted snap ring is 2.0 3.2 mm through the circumference. a Hold the ring gear and move it up and down. Check that carrier does not come off at this time.
7) Set collar (121) between 2 bearings (120) and install them to No. 5 planetary gear (119). Fit thrust washers (122) to both sides of them and set them to the carrier. 8) Drive shaft (117), matching the bearing to the thrust washer. 9) Drive out shaft (117) until the ball hole is seen perfectly, then fit ball (118) and drive the shaft into the carrier. a When driving the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. a Check that the gear rotates smoothly.
10) Install bearing (115) and seal ring (116) to the carrier assembly. Periphery of seal ring: Grease (G2-LI)
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10. No. 4 and No. 5 carriers assembly Using hanging bolts, sling the shaft. Install No. 4 and No. 5 carriers assembly (201), matching the gear to the bearing. You can install the "No. 4, No. 5 carriers, No. 6, and No. 7 assembly", too, as you removed. If this assembly is slung and moved, however, the bearing in the intermediate position may come off. Accordingly, divide this assembly.
2) Install gear (86). 3) Install snap ring (85).
11. No. 5 clutch sun gear Install sun gear (113). Take care not to have your fingers caught in the gears.
13. No. 6 clutch discs, plates, and springs Install plate (110), discs (108), plates (109), and springs (111) and (112). Install the 4 discs, 4 plates (109), and 1 plate (110). Install one of plates (109) on the top. Check that springs (111) are fitted to the seats of the piston and housing. Securely install 6 springs (112) to each disc.
12. No. 4 clutch sun gear 1) Install seal ring (200) to gear (86). Periphery of seal ring: Grease (G2-LI)
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TRANSMISSION
14. No. 5 housing, piston, ring gear, and guide pins 1) Install tie bolt sleeves (203) to No. 5 housing (99). When installing the sleeve, set slit A at the position checked when removed. When tie bolts (83) are installed, they become hard because of the cushion sleeves. At this time, do not drive them forcibly with a hammer. (For prevention of breakage)
15. No. 5 clutch, discs, plate, and springs Install discs (95), plate (96), and springs (97) and (98). Install the 5 discs and 4 plate. Securely install 6 springs (98) to each disc.
2) Install seal rings (106) and (107) to housing (99) and piston (102), then install the piston to the housing. Install the seal ring as shown in the following figure. Periphery of seal ring: Grease (G2-LI)
3) Set No. 5 clutch ring gear (103). Set the gear with the chamfered side up. 4) Using hanging bolts, install No. 5 housing (99), matching it to the spring. If the dowel pin is hard, drive it with a plastic hammer. 5) Install guide pins (202).
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16. No. 4 housing, piston, and ring gear 1) Install seal rings (93) and (94) to housing (91) and piston (92), then install the piston to the housing. Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)
2) Using sling bolts, install No. 4 housing, matching it to the spring. Check that the springs are fitted to the seats of the piston and plate. If the dowel pin is hard, drive it with a plastic hammer. 3) Install ring gear (93). Set the gear with the chamfered side up. 18. No. 4 clutch plate Install plate (84). Check that the springs are fitted to the seats of the piston and plate. 19. Tie bolts Install tie bolts (83). Press in each bolt to the end of the cup hole. Do not use a hammer at this time. Do not use an impact wrench until the bolt catches the threads. Tie bolt: 156.9 176.5 Nm {16 18 kgm}
17. No. 4 clutch, discs, plate, and springs Install plate (101), discs (87), plates (88), and springs (89) and (90). Install the 4 discs, 3 plates (88), and 1 plate (101). Securely install 6 springs (89) to each disc.
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TRANSMISSION
20. No. 3 clutch ring gear 1) Install inner race (81) and seal ring (82) to the ring gear. Periphery of seal ring: Grease (G2-LI)
2) Install No. 3 clutch ring gear (80). Mounting bolt: Adhesive (LT-2) Mounting bolt: 156.9 196 Nm {16 20 kgm}
22. Check of operation of piston Using tool D1, check the operation of pistons of No. 4, 5, 6, and 7 clutches. a Air pressure: 0.29 0.59 MPa {3 6 kg/cm2} Standard stroke of piston
Piston No. 4 5 6 7 Stroke (mm) 4.8 5.8 5.0 5.0
a If the pistons do not move smoothly, apply engine oil to them.
21. No. 3 clutch housing assembly a For sassembly, see Step 24, assembly of No. 2 clutch assembly, 5) 8). (No. 3 clutch assembly has the same structure as No. 2 clutch assembly.) a The plates, discs, and springs are each 1 less than those of No. 2 clutch assembly. a Using hanging bolts, sling and install housing assembly (75), matching the internal teeth of the disc to the external teeth of the ring gear. Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 122.5 Nm {10 12.5 kgm}
23. Transmission case 1) Install the following parts to the transmission case. i) Install seal ring (204) to the outer groove of collars (73), then install them, matching to the dowel pin of the transmission case. Periphery of seal ring: Grease (G2-LI) ii) Install cage (71). iii) Install bearings (72) and (74) to both sides. a Press fit the bearings until they are stopped by collars (73).
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When driving the shaft, align it with th e b ear in g a nd av oid hi tti ng it strongly so that the bearing cage will not be deformed. iv) Fit ball (64) and install shaft (61) securely. If the shaft moves out, caulk the carrier side with a punch. Check that the gear rotates smoothly.
2) Install the O-ring to the transmission case. 3) Sling and install transmission case (70) and tighten cage assembly mounting bolts (69).
2) Install plate (59) to carrier (60). Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 122.5 Nm {10 12.5 kgm}
24. Assembly of No. 2 clutch assembly 1) Carrier assembly i) Install inner race (67), bearing (68), and seal ring (66) to carrier (60). Periphery of seal ring: Grease (G2-LI)
3) Turn over the carrier assembly. Using sling bolts, install drum (58), matching it to the gear of the carrier.
ii) Install bearing (65) to gear (63). Fit thrust washers (64) to both sides of them and set them to the carrier. iii) Matching the thrust washer to the bearing, drive shaft (61).
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4) Install the ring gear (54), matching it to the carrier, and secure it with snap ring (53). 5) Discs, plates, and springs Install discs (55), plates (56), and springs (57) between the drum and ring gear. Install the 5 discs, 4 plates, and 5 springs.
8) Install piston (45) to the housing, then install cover (44). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
6) Housing assembly i) Install inner race (51) and bearing (52) to the housing. ii) Install ball (205) and bushing (50), then secure them with snap ring (49). iii) Install seal rings (47) and (48). Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)
9) Install housing (43) to the drum. Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 122.5 Nm {10 12.5 kgm}
25. No. 2 clutch assembly Using sling bolts, sling and install No. 2 clutch assembly (42), matching the external teeth of the piston to the internal teeth of the drum. 7) Install seal ring (46) to piston (45). Install the seal ring as shown below. Periphery of seal ring: Grease (G2-LI)
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26. Input shaft and No. 1 ring gear assembly 1) Press fit bearing (40) to input shaft (41) and install snap ring (39).
4) Install inner race (35) to No. 1 ring gear (34).
2) Install inner race (38) to gear (37).
5) Install ring gear (34) and seal rings (206) and (207) to the input shaft. Periphery of seal ring: Grease (G2-LI)
3) Install gear (37) to the outer race side of the bearing, then install snap ring (36).
6) Sling the input shaft and install the input shaft and No. 1 ring gear assembly (33), matching the gear to the bearing.
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TRANSMISSION
27. No. 1 clutch, drum, and piston 1) Install seal rings (100) and (101) to piston (32), then install them to the drum (31). Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI) 2) Using sling bolts, install No. 1 clutch drum (31) and piston (32) together.
29. No. 1 clutch plate 1) Install bearing (25) to No. 1 clutch plate.
2) Using sling bolts, install plate (24), matching it to the spring and guide. Mounting bolt: 156.9 - 196 Nm {16 20 kgm}
28. No. 1 clutch discs, plates, and springs Install discs (28), plates (29), springs (26) and (30), and guide (27). Install the 3 discs and 2 plates.
30. Check of operation of piston Using tool D1, blow air into the clutch ports and check the operation of the pistons of No. 1, 2, and 3 clutches. (Since you cannot check the operation of the pistons of No. 2 and 3 clutches directly, check it by movement of the discs or plates.) The locations of the clutch ports are shown below. No. 1 clutch port: A No. 2 clutch port: B No. 3 clutch port: C Air pressure: 0.29 0.59 MPa {3 6 kg/cm2} Standard stroke of clutch No. 1 piston 4.2 mm
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HD465-7, HD605-7
TRANSMISSION
31. Oil pan 1) Install relief valves (22) and (23) to the oil pan, then install blocks (20) and (21).
32. Sleeve Fit the O-rings to sleeves (14) and install them to the transmission.
2) Install magnet assembly (19) and spring (18) to the oil pan, then fit the O-ring and install cover (17).
3) Fit the plate gasket to oil pan (16) horizontally, then sling and install transmission assembly (15). Both sides of plate gasket: Gasket sealant (LG-1)
33. Control valve assembly 1) Install each control valve (12) to the valve seat. Control valve: 8.0 10.0 Nm {0.8 1.0 kgm} 2) Install filter assembly (13). If the filter case and filter bracket plug were removed, tighten them to the following torque. Filter case: 34.3 44.1 Nm {3.5 4.5 kgm} Plug: 15.7 19.2 Nm {1.6 2.0 kgm} 3) Install sling bolts to A, then install the valve seats and control valve assembly (11) together. Mounting bolt: Gasket sealant (LG-5) 4) Install wiring harness (10) and connect the connectors to each control valve.
HD465-7, HD605-7
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TRANSMISSION
34. Sensors, wiring harness, covers, and transmission mounts 1) Install block (9). 2) Install lubricating oil temperature sensor (8) and cover (7).
3) Install output shaft speed sensor (6), intermediate shaft speed sensor (5), and input shaft speed sensor (4). For installation procedure, see TESTING AND ADJUSTING, Adjusting transmission speed sensors.
4) Install covers (2) and (3). 5) Install both transmission mounts (1).
30-66
HD465-7, HD605-7
DIFFERENTIAL
REMOVAL AND INSTALLATION OF DIFFERENTIAL ASSEMBLY

REMOVAL
Apply the parking brake and put blocks under the wheels. 1. Remove the dump body assembly. For details, see REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY". 2. Drain oil from the differential case and final drive case. Differential case: 95 Final drive case (Each side): 21 3. Using guide bolts [1], remove cover (1). (The rear wheel assembly is removed in the following photo. It does not need to be removed, however.)
5. Remove guard (3) and drive shaft (4). 6. Disconnect hoses (5), (6), and (7) and remove slack adjuster (8).
7. Using forcing screws [2] and guide bolt [3], pull out differential assembly (9) forward. Differential assembly: 850 kg
4. Pull out drive shaft (2). Install a hanging bolt to the shaft end to pull out the shaft. Drive shaft: 110 kg
HD465-7, HD605-7
30-67
DIFFERENTIAL
INSTALLATION
Drain plug (Center of cover on final drive case side): 127.4 176.4 Nm {13.0 17.9 kgm} (Periphery of cover on final drive case side): 24.5 34.3 Nm {2.5 3.4 kgm}
Before tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke. Mounting bolt: Adhesive (LT-2) Mounting bolt: 157 196 Nm {16.0 19.9 kgm}
Mounting bolt: 455 565 Nm {46.4 57.6 kgm}
Refilling with oil Differential case: 95 (EO30-CD)
Final drive case (Each side): 21
(EO30-CD)
30-68
HD465-7, HD605-7
DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY

Special tools
4. Bevel pinion and cage assembly 1) Lift off bevel pinion and cage assembly (5). Before removing the bevel pinion and cage assembly, make match marks on the cage and differential case. Check the thickness, quantity, and location of shim (6).
Sketch
Part No.
Part name
790-501-5000 1 H 790-901-5110 790-901-3420 2 3 4 790-425-1660 790-102-1130 797-101-1171
Unit repair stand Bracket Plate Wrench
Power wrench assembly Wrench
DISASSEMBLY
1. Tool of differential assembly Set the differential assembly to tool H1. 2. Coupling Remove holder (1) and coupling (2). 2) Using press [2], press down bevel pinion assembly (7) and remove it and bearing (8) together from cage assembly (9). Set a block, etc. under the bevel pinion assembly to prevent the assembly from falling to the floor.
3. Cage 1) Using forcing screws [1], remove cage (3). Before removing the cage, make match marks on it and differential case. 2) Remove oil seal (4) from cage (3).
Q'ty 1 1 1 1 1 1
HD465-7, HD605-7
30-69
DIFFERENTIAL
3) Disassembly of bevel pinion assembly Remove spacer (11) and bearing (12) from bevel pinion assembly (10).
4) Disassembly of cage assembly Remove outer races (14) and (15) from cage (13).
4) Sling differential gear assembly (20) temporarily. 5) Using tool H3, remove 4 bearing cap bolts (21). 6) Remove bearing caps (22) and (23) and adjustment nuts (18) and (19). 5. Removal of differential gear assembly 1) Turn over tool H1. 2) Remove locks (16) and (17). 3) Using tool H2, loosen adjustment nuts (18) and (19) until you can turn them with the hand.
30-70
HD465-7, HD605-7
DIFFERENTIAL
7) Remove outer races (24) and (25) from both bearings and lift off differential gear assembly (20).
3) Remove bearing (29) from case (27).
4) Remove side gear (30). 6. Disassembly of differential gear assembly 1) Lift off case and bearing assembly (26). Before removing the assembly, make match marks on the top and bottom of the case.
5) Remove cross shaft and pinion gear assembly (31).
2) Remove washer (28) from inside of case (27).
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DIFFERENTIAL
6) Remove pinion gear assembly (33) from cross shaft (32).
10) Remove washer (38).
11) Turn over the case and bevel gear assembly. 7) Using tool H4, remove nut (34). 8) Remove sleeve (35) and the bearing. The bearing is an assembly of large bearing A, small bearing B , outer race spacer C, and inner race spacer D . 12) Remove bevel gear (39) from case (40). Before removing the bevel gear, make match marks on it and the case. 13) Remove bearing (41).
9) Remove side gear (37).
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HD465-7, HD605-7
DIFFERENTIAL
ASSEMBLY
Clean the all parts and check them for dirt or damage. Coat the sliding surfaces with engine oil (EO30CD) before installing. 1. Assembly of differential gear assembly 1) Install bearing (41) to case (40) by shrink fit. Shrink fit temperature of bearing: Keep at 120C for 30 min. After installing the bearing, drop engine oil (EO30-CD) over it. 2) Install bevel gear (39) to case (40). When installing, match the match marks. Mounting bolt: Adhesive (LT-2) Mounting bolt: 455 565 Nm {46.4 57.6 kgm}
After installing the washer, check that distance a between the washer surface and the end of dowel pin E is 0.35 0.75 mm. (If the dowel pin has been removed, drive it to the above dimension.)
5) Install side gear (37).
3) Turn over the case and bevel gear assembly. 4) Install washer (38). Install the washer with the grooved side up.
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DIFFERENTIAL
6) Install the bearing to the pinion gear. Drop engine oil (EO30-CD) over the sliding parts. The bearing is an assembly of large bearing A , small bearing B, outer race spacer C, and inner race spacer D. Do not change the combination of the above parts. (The same combination mark is stamped on each part.) 7) Install sleeve (35) as shown in the following figure. 8) Using tool H4, tighten nut (34). Nut: 490 408 Nm {50.0 61.9 kgm} After tightening the nut, rotate the bearing 5 turns or more to check that it rotates lightly.
10) Install cross shaft and pinion gear assembly (31).
11) Install side gear (30).
9) Install pinion gear assembly (33) to cross shaft (32).
12) Install bearing (29) to case (27) by shrink fit. Shrink fit temperature of bearing: Keep at 120C for 30 min. After installing the bearing, drop engine oil (EO30-CD) over it.
30-74
HD465-7, HD605-7
DIFFERENTIAL
13) Turn over case (27) and install washer (28). Install the washer with the grooved side up.
2. Installation of differential gear assembly 1) Sling differential gear assembly (20) to the installation position of the differential case. Keep the differential gear assembly above the differential case. 2) Install outer races (24) and (25) to both bearings. Drop sufficient amount of engine oil (EO30-CD) over the bearings. 3) Install adjustment nuts (18) and (19) to the differential case temporarily.
After installing the washer, check that distance a between the washer surface and the end of dowel pin E is 0.35 - 0.75 mm. (If the dowel pin has been removed, drive it to the above dimension.)
14) Sling and install case and bearing assembly (26). When installing, match the match marks.
4) Install bearing caps (22) and (23). 5) Using tool H3, tighten 4 bearing cap bolts (21). Before tightening the bearing cap bolts, rotate the bevel gear 20 - 30 turns to fit the bearing. Mounting bolt: Adhesive (LT-2) Mounting bolt: 2,450 3,040 Nm {249.9 309.9 kgm} Before installing the locks for fixing the adjustment nuts, finish the following "Adjusting preload on bearing", "Adjusting backlash", "Testing tooth contact", and "Adjusting tooth contact".
HD465-7, HD605-7
30-75
DIFFERENTIAL
4. Bevel pinion and cage assembly 1) Assembly of cage assembly Install outer races (14) and (15) to cage (13). Press fit the outer races until they are stopped by the cage.
3. Adjusting preload on bearing Press push-pull scale [3] against the periphery of bevel gear (39) and measure the starting tangential force in the tangential direction. Standard starting tangential force: 39.2 62.8 N {4.0 6.4 kg} [Target: 51.0 N {5.2 kg}] If the starting tangential force is below the standard value, tighten the adjustment nuts on both sides with tool H2 . If the former exceeds the standard value, loosen the adjustment nuts on both sides. When adjusting, rotate the bevel gear so that the bearings will be fitted sufficiently.
2) Assembly of bevel pinion assembly i) Install bearing (12) to bevel pinion (10) by shrink fit or press fit it to the end with the push tool. Shrink fit temperature of bearing: Keep at 120C for 30 min. After installing the bearing, drop engine oil (EO30-CD) over it. ii) Install spacer (11). Reference: This spacer is a part of cage assembly (13) shown above.
30-76
HD465-7, HD605-7
DIFFERENTIAL
3) Place cage assembly (9) on bevel pinion assembly (7). 4) Install bearing (8). 5) Using push tool [4] and revolving cage assembly (9), press fit bearing (8) to the end. Drop engine oil (EO30-CD) over bearing (8). Do not use a press to press fit the bearing. 6) Hold bevel pinion assembly (7) and revolve cage assembly (9) with the push-pull scale and measure the starting tangential force in the tangential direction. Standard starting tangential force: Max. 24.5 N {2.5 kg} If the starting tangential force exceeds the standard value, replace bearings (8) and (12) or cage assembly (9) and measure again. Check that the starting tangential force is in the standard range.
5. Cage 1) Install oil seal (4) to cage (3). Press fit the oil seal until it is stopped by the cage. Outer ring of oil seal: SEALEND 242 or equivalent Lip of oil seal: Grease (G2-LI) 2) Fit the O-ring and cage (3). When installing, match the match marks. Mounting bolt: 455 565 Nm {46.4 57.6 kgm}
7) Install shim (6) of the thickness and quantity checked when disassembled. Fit the O-ring and sling and install bevel pinion cage assembly (5). Thicknesses of shims: 0.2 mm, 0.3 mm, 1.0 mm When installing, match the match marks.
3) Set dial gauge [5] on the top of bevel pinion assembly (7). Move the bevel pinion assembly in the thrusting direction and measure the end play. Standard end play: 0 0.15 mm If the end play exceeds the standard value, replace bearings (8) and (12) or cage assembly (9) and measure again. Check that the end play is in the standard range.
HD465-7, HD605-7
30-77
DIFFERENTIAL
6. Coupling 1) Install coupling (2), O-ring, and holder (1). Rotate the bevel gear to rotate the bevel pinion 20 30 turns and tighten the mounting bolts gradually. Mounting bolt: Adhesive (LT-2) Mounting bolt: 1,520 1,910 Nm {155.0 194.7 kgm} 2) Rotate the coupling 20 30 turns, and then check that the holder mounting bolts are tightened to the specified torque.
3) If the backlash is out of the standard range, adjust it by moving the bevel gear. Move the bevel gear with tool H2 and adjustment nuts (18) and (19). If either adjustment nut is tightened (loosened), loosen (tighten) the other adjustment nut by the same angle so that the preload applied to bearings (29) and (41) (in Step 3) will not change.
7. Adjusting backlash 1) Apply the probe of dial gauge [5] to a tooth tip of the bevel gear at right angles. 2) Fix the bevel pinion and move the bevel gear forward and backward (in the revolving directions) and read the dial gauge. Standard backlash: 0.41 0.56 mm Measure the backlash at 3 4 places and check that the difference between the measured values is 0.1 mm or less.
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HD465-7, HD605-7
DIFFERENTIAL
When the backlash is below standard value Loosen adjustment nut (19) on the bevel gear side and tighten adjustment nut (18) on the right side by the same angle (to move the bevel gear in the direction of A). When the backlash is above standard value Loosen adjustment nut (18) on the right side and tighten adjustment nut (19) on the bevel gear side by the same angle (to move the bevel gear in the direction of B).
9. Adjusting tooth contact If the tooth contact pattern is not proper, adjust the tooth contact according to the procedure shown in the following page. Adjust the toot contact by increasing or decreasing shim (6) (to move the bevel pinion) and revolving the adjustment nuts (to move the bevel gear: See Adjusting backlash). After adjusting the tooth contact, check the backlash again.
8. Testing tooth contact Apply red lead thinly to the surfaces of 7 8 teeth of the bevel gear and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. The center of the tooth contact must be as follows. Middle of tooth height Point on tooth at distance of x from small end C (x = 46 6 mm) Width y of the tooth contact must be 41 82 mm. Check that there is not a strong contact at tip A, bottom B, small end C, or large end D.
HD465-7, HD605-7
30-79
DIFFERENTIAL
Tooth contact
Cause
Adjusting method
Bevel pinion is too far from bevel gear.
1. Reduce shim (6) to move bevel pinion close to bevel gear. 2. Move bevel gear away from bevel pinion.
Bevel pinion is too close to bevel gear.
1. Increase shim (6) to move bevel pinion away from bevel gear. 2. Move bevel gear close to bevel pinion.
Bevel gear is too close to bevel pinion.
1. Reduce shim (6) to move bevel pinion close to bevel gear. 2. Move bevel gear away from bevel pinion.
Bevel gear is too far from bevel pinion.
1. Increase shim (6) to move bevel pinion away from bevel gear. 2. Move bevel gear close to bevel pinion.
10. Locks Install locks (17) and (16) of the adjustment nuts.
30-80
HD465-7, HD605-7
FRONT WHEEL
REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the rear wheels with blocks. 1. Set a hydraulic jack (50 t) under arm (1) and raise the front wheel assembly.
4. Remove wheel assembly (3) with a forklift, etc. Wheel assembly: 1,000 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down. Take care not to break the air valves.
INSTALLATION
2. Support the frame on a stand, etc. Tighten the hub nuts evenly in the diagonal order. Tighten the hub nuts permanently after lowering the truck body. Hub nut: 1,519 1,617 Nm {154.9 164.8 kgm} After installing the wheel assembly, drive the truck about 5 - 6 km, then check that the hub nuts are tightened to the specified torque. Carry out installation in the reverse order to removal.
3. Remove hub nuts (2).
HD465-7, HD605-7
30-81
REAR WHEEL
REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the front wheels with blocks. 1. Set a hydraulic jack (50 t) under either rear axle and raise the rear wheel assembly.
5. Remove inner hub nuts (4).
2. Loosen the locknut of the air valve and remove lock plate (1). 3. Remove outer hub nuts (2). 6. Remove wheel assembly (5) with a forklift, etc. Wheel assembly: 850 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down.
4. Remove wheel assembly (3) with a forklift, etc. Wheel assembly: 850 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down.
30-82
HD465-7, HD605-7
REAR WHEEL
INSTALLATION
Carry out installation in the reverse order to removal. , Tighten the hub nuts evenly in the diagonal order. Tighten the hub nuts permanently after lowering the truck body. Hub nut: 1,519 1,617 Nm {154.9 164.8 kgm} After installing the wheel assembly, drive the truck about 5 - 6 km, then check that the hub nuts are tightened to the specified torque.
HD465-7, HD605-7
30-83
FRONT BRAKE CALIPER PADS
REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPER PADS

REMOVAL
1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Pull out torque pin (1). a Pin fixing bolt (2) and pull out pin (1) to a degree that you can remove the pads.
INSTALLATION
a Push in the torque pin and fix it with the bolt securely. a Adjust the clearance between the pin and disc to 1.5 3 mm. Pin fixing bolt: 51.5 2.5 Nm {5.25 0.25 kgm} a For precautions for installing the pin fixing bolt, see DISASSEMBLY, ASSEMBLY OF FRONT BRAKE CALIPERS ASSEMBLY. a Bleed air from the front brake circuit. For details, see TESTING AND ADJUSTING, Bleeding air from brake circuit.
3. Remove pads (3). 1) Install a vinyl hose to bleeder screw (4) so that the brake oil will be drained. 2) Loosen the bleeder screw and return pistons (5) with a bar to the bottoms of the cylinders.
30-84
(10)
HD465-7, HD605-7
FRONT BRAKE CALIPERS
REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS ASSEMBLY

REMOVAL
1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Disconnect hose (1). 3. Sling the calipers assembly temporarily and remove bolts (2).
INSTALLATION
Mounting bolt: Adhesive (LT-2) Mounting bolt: 785 980 Nm {80.1 100 kgm} a Bleed air from the front brake circuit. For details, see TESTING AND ADJUSTING, Bleeding air from brake circuit.
4. Remove calipers assembly (3). a Sling the calipers assembly, adjusting it with a lever block, etc. Calipers assembly: 75 kg
HD465-7, HD605-7
30-85
(10)
DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE CALIPERS ASSEMBLY

DISASSEMBLY
1. Pin fixing bolts (1) and (2) and remove torque pins (3), (4), and (5) and pads (6). 2. Remove plate (7), plug (8), backup ring (9), and seal (10). 3. Remove dust seal (11) and piston (12). 4. Remove seal (13) and backup ring (14). a Disassemble the other pistons similarly.
ASSEMBLY
1. Fit backup ring (14), seal (13), and dust seal (11) to the grooves of torque plate (15). 2. Install piston (12). a Fit the dust seal lip to the groove of the piston. 3. Install seal (10), backup ring (9), plug (8), and plate (7). 4. Install pads (6) and torque pins (5), (4), and (3) and tighten pin fixing bolts (2) and (1). Bolt: 51.5 2.5 Nm {5.25 0.25 kgm} a Unlike a usual bolt, each of the above bolts has pointed end (part "a"). The pointed end bites in the surface of torque pin (5) (deforms the pin plastically) (Bitten part: "b", Trace of biting: " c) to fix the pin. (The bolt must be tightened further after resistance is felt.) Accordingly, if the bolt is not tightened to the specified torque, it cannot bite in and fix the pin sufficiently. a Move the pin in the axial direction, tightening the pin fixing bolts, check that the bolts are fitted in the grooves of the torque pin.
30-86
(4)
HD465-7, HD605-7
a Be sure to install torque pin (4), (5) which is shorter than torque pin (5) to the plate side. a Assemble the other pistons similarly. 5. Install the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. a Install the front brake calipers assembly so that clearance " d" between disc plate (16) and torque pin (3) will be 1.5 to 3.0 mm.
HD465-7, HD605-7
30-87
(10)
FRONT WHEEL HUB
DISASSEMBLY AND ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY

DISASSEMBLY
1. Front brake calipers assembly Remove the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. 2. Cover Remove cover (1). 3. Wheel hub assembly 1) Support wheel hub assembly (2) with a forklift. 2) Remove retainer (3). a Check the quantity of the shims and store them. 5) Disassemble wheel hub assembly according to the following procedure. i) Remove the mounting bolts and brake disc (5). ii) Remove oil seal (6). iii) Remove outer race (7). iv) Remove outer race (8).
4. Bearing and retainer 1) Remove bearing (10). 2) Remove retainer (11).
3) Slant wheel hub assembly (2) lightly from the rear and press it and bearing (4) out together. 4) Remove bearing (4) and wheel hub assembly (2). Wheel hub assembly: 330 kg
30-88
(10)
HD465-7, HD605-7
FRONT WHEEL HUB
ASSEMBLY
1. Retainer and bearing 1) Install retainer (11). 2) Install bearing (10).
2. Wheel hub assembly 1) Assemble the wheel hub assembly according to the following procedure. i) Using the push tool, press fit outer race (8). ii) Using the push tool, press fit outer race (7). iii) Using the push tool, press fit oil seal (6). a Degrease the sealing side of wheel hub A and periphery of the seal. a Degrease part B. Periphery of seal: Adhesive: (Loctite No. 648) Space c of seal lip: Fill with grease (See Table 1). Table 1
No. 1 2 3 4 Manufacturer NIHON KOYU SHELL OIL ESSO OIL BP Brand of grease HIREX HD-2 Super Duty Grease 2 RONEX MP Energrease LS-EP2
iv) Set brake disc (5) and tighten the mounting bolts. 2) Support and install wheel hub assembly (2) with a forklift.
Fill the shaded parts in the following figure with sufficient amount of grease. (Grease: 9 for each wheel hub assembly) a Take care not to damage the oil seal on the inside of the hub. a Select the grease from Table 1. Table 1
No. 1 2 3 4 Manufacturer NIHON KOYU SHELL OIL ESSO OIL BP Brand of grease HIREX HD-2 Super Duty Grease 2 RONEX MP Energrease LS-EP2
HD465-7, HD605-7
30-89
(3)
FRONT WHEEL HUB
a Fill the hatched space between the rollers of the bearing until it is projected from the opposite side of the retainer.
3) Install bearing (4).
5) Install the shims and retainer (3). Revolving the hub 20 30 turns, tighten the bolts evenly to the specified torque.. Mounting bolt: 455 565 Nm {46.4 57.6 kgm} a After tightening the bolts, rotate the hub and check that it rotates normally.
4) Adjust the preload on the bearing according to the following procedure. i) Install retainer (3) without inserting any shim with 3 mounting bolts. Revolving the hub 20 30 turns, tighten the bolts evenly to the specified torque. Mounting bolt (For adjustment): 103 113 Nm {10.5 11.5 kgm} ii) Measure distance c between the retainer and axle end with depth micrometer [1]. a Measure at 2 places and obtain the average. iii) Remove retainer (3) and measure its thickness T. Add 0.3 mm to the difference between above distance c and thickness d (c T), then use the result as the shim thickness. a Measure at 2 places and obtain the average. a Combine the shims so that their quantity will be minimum. a When removing the retainer, take care that the bearing will not come off.
3. Cover Fit the O-ring and install cover (1). Fill the inside of cover (hatched part) with grease. a Use grease of the brand used for the wheel hub in 2-2).
4. Front brake calipers assembly Install the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. HD465-7, HD605-7
30-90
(10)
FINAL DRIVE CARRIER
REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY

REMOVAL
The rear wheel assembly is removed in the following photo. It does not need to be removed, however.
5. Using guide bolts [2] and forcing screws [3], pull out and remove carrier assembly (6). When the carrier assembly comes off the guide bolts, it is unbalanced suddenly. Accordingly, insert a bar in the center shaft hole to balance the carrier assembly. Carrier assembly: 220 kg
1. Remove the drain plug of the cover and drain oil from the final drive case. Final drive case: 32 (Each side)
2. Using guide bolts [1], remove cover (1).
INSTALLATION
3. Pull out drive shaft (2). Install a sling bolt to the shaft end to pull out the shaft. Drive shaft: 110 kg 4. Remove snap ring (3), sun gear (4), and spacer (5).
Drain plug (Center of cover on final drive case side): 127.4 176.4 Nm {13.0 17.9 kgm} (Periphery of cover on final drive case side): 24.5 34.3 Nm {2.5 3.4 kgm}
Carrier assembly mounting bolt: 455 565 Nm {46.4 57.6 kgm} Refilling with oil Final drive case (Each side): 32
(EO30-CD)
HD465-7, HD605-7
30-91
FINAL DRIVE CARRIER
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE CARRIER ASSEMBLY

DISASSEMBLY
1. Drive out shaft (1) by hitting it outward. Take care not to lose ball (2). 2. Remove planetary gear (3) and bearing (4).
ASSEMBLY
1. Install bearing (4) to planetary gear (3). 2. Set planetary gear (3) to the case. Securely match the planetary gear to the hose on the case side. 3. Matching the ball hole of shaft (1) to the cut for the ball on the case side, press fit the shaft until the ball hole comes in contact with the case end. 4. Install ball (2) and press fit shaft (1) to the end.
30-92
HD465-7, HD605-7
FINAL DRIVE AND REAR BRAKE
REMOVAL AND INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY

Special tools
a Fix outer gear (5) and wheel hub (6) at following points a, b, c and d (4 points in total).
792T-422-1610 J 1 01011-61620 01643-31645
Spacer Bolt Washer
t t t
4 4 4
REMOVAL
1. Remove the dump body assembly. For details, see REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY". 2. Remove the (outer and inner) rear wheel assemblies on the side of the final drive and rear brake assembly to be removed. For details, see REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY. 3. Remove the final drive carrier assembly. For details, see REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY. 4. Release the parking brake. For details, see TESTING AND ADJUSTING, method of releasing parking brake in an emergency. 5. Using tool J1, fix outer gear (5) and wheel hub (6). a Be sure to install tool J1 to protect the floating seal before removing the retainer.
Sketch
Part No.
Part name
Q'ty
6. Remove retainer (7) and shim (8). a Before removing the retainer completely, pass a guide bolt through the retainer, and then pull out the retainer and ring gear assembly together slowly and sling them. a Check the thickness and quantity of the shims.
7. Remove ring gear assembly (9). Ring gear assembly: 100 kg
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8. When disassembling the ring gear assembly, remove bolt (10) and take the assembly apart into holder (11), inner hub (12), and ring gear (13).
a Since bearing (16) comes off, take care not to drop it.
9. Sling final drive and rear brake assembly (14) temporarily. 10. Remove 31 bolts (15) and pull out final drive and rear brake assembly (14) sideway to remove it. Final drive and rear brake assembly: 800 kg
a For disassembly and assembly, see DISASS E M B LY A N D A S S E M B LY O F F I N A L DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY.
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INSTALLATION
Carry out installation in the reverse order to removal. After installing, be sure to remove tool J1 and parking brake releasing bolt.
Adjusting preload on bearing 1) Install retainer (7) without inserting any shim and tighten 3 mounting bolts to the following torque. a Rotating the hub 20 30 turns, tighten the bolts evenly to the specified torque. Retainer mounting bolt: 181 191 Nm {18.5 19.4 kgm} [Target: 186 Nm {18.9 kgm} 2) Measure distance a between the end of tube (17) and end of retainer (7) with depth micrometer [2]. a Measure at 2 places and obtain the average. 3) Remove retainer (7) and measure its thickness b. a Measure at 2 places and obtain the average. 4) Calculate shim thickness c by the following expression. c (mm) = a b + 0.3 5) Install the shim of the calculated thickness and retainer (7) with the all mounting bolts (6 bolts). a Rotating the hub 20 30 turns, tighten the bolts evenly to the specified torque. Mounting bolt: 785 980 Nm {80.1 99.9 kg} 6) Rotate the wheel hub again and check that it revolves normally.
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FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE
REMOVAL AND INSTALLATION OF FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY
REMOVAL
1. Perform Steps 1 - 7 of REMOVAL AND INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY. a If the final drive, rear brake, and parking brake assembly does not need to be disassembled after removed, the parking brake does not need to be released. 2. Disconnect hoses (1) and (2) and remove pipes (3) and (4). a Since bearing (16) comes off, take care not to drop it.
3. Sling final drive, rear brake, and parking brake assembly (5) temporarily. 4. Remove 30 nuts (6) and pull out final drive, rear brake, and parking brake assembly (5) sideway to remove it. Final drive, rear brake, and parking brake assembly: 1,100 kg
INSTALLATION
Mounting nut of final drive, rear brake, and parking brake assembly: 455 565 Nm {46.4 57.6 kgm} Adjusting preload on bearing See REMOVAL, INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY.
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DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY
Special tools
3. Parking brake assembly 1) Check that the parking brake is released. (See TESTING AND ADJUSTING, Method of releasing parking brake in an emergency.) 2) Remove parking brake assembly (1). a Make match marks on parking brake assembly (1) and outer gear (5) for reference for installation.
792T-422-1610 1 01011-61620 01643-31645 J 2 3 795-102-2102 792-520-2110 792-530-1600 791-585-1510 791-530-1700
Spacer Bolt Washer Spring washer Installer Push tool Installer Push tool
t t t t t t t t
4 4 4 1 1 1 1 1
For the sketch of tool J1, see SKETCH OF SPECIAL TOOL.
Sketch
Part No.
Part name
Q'ty
4. Disassembly of parking brake assembly Since the installing load on the internal spring is large, disassemble the assembly carefully according to the following procedure. 1) Gradually loosen and remove parking brake releasing bolts A (10 pieces). a Loosen all releasing bolts A evenly so that the internal brake piston will not slant. Reference: Total installing load on spring: Approx. 199 kN {20.3 ton}
DISASSEMBLY
Remove the internal parts (piston, damper, disc, plate, floating seal, etc.) carefully so that they will not be damaged by impacts, fall, etc. 1. Place the final drive, rear brake, and parking brake assembly with the parking brake side up. Using blocks, etc., place the assembly stably. 2. Remove tool J1 which is fixing outer gear (5) and wheel hub (6).
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2) Turn over the parking brake assembly. 3) Gradually and evenly loosen and remove 13 cylinder mounting bolts (4).
6) Remove seal rings (8) and (9) from cylinder (7).
4) Remove cylinder (7). a Make match marks on cylinder (7) and piston assembly (3) for reference for installation.
7) Remove 30 springs (10) from cylinder (2). a There are 22 double springs and 8 single springs. a Make distinction marks at locations of the single springs (8 places) with paint for reference for installation.
5) Remove piston assembly (3). a Make match marks on piston assembly (3) and cylinder (2) for reference for installation.
8) Turn over the piston assembly disassembled in Step 5). 9) Using tool J2, compress the springs and remove pin (11), washer (12), spring (13), and guide (14).
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5. Dampers, discs, plates, and spacer 1) Remove plates (19).
10) Remove parking brake piston (15). Make match marks on parking brake piston (15) and brake piston (16) for reference for installation.
2) Remove damper (20), 12 discs (21), 11 plates (22), and damper (23).
11) Remove seal rings (17) and (18) from brake piston (16).
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HD465-7, HD605-7
3) Install bolts [3] to the sling taps and remove spacer (24).
7. Inner gear 1) Remove inner gear (27).
6. Outer gear 1) Remove outer gear (5). Take care not to drop the floating seal from the bottom.
2) Remove floating seal (28) on the outside of the inner gear, retainer (29), and floating seal (30) on the inside of the inner gear.
2) Remove oil seal (25) and floating seal (26) from outer gear (5).
8. Wheel hub assembly 1) Remove retainer and floating seal assembly (31). Retainer and floating seal assembly (31) is free when the inner gear (in the previous section) is removed.
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2) Remove floating seal (33) from retainer (32).
3) Remove bearing (34).
4) Remove outer races (35) and (36).
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HD465-7, HD605-7
ASSEMBLY
Clean the all parts and check them for dirt or damage. Coat the sliding surfaces with engine oil before installing. Remove the white powder from the O-ring surface of the floating seal with engine oil, etc. Even a slight flaw of the floating seal made by an impact, fall, etc. can cause oil leakage. Accordingly, install the floating seal carefully. 1. Wheel hub assembly 1) Install outer races (35) and (36).
4) Set retainer and floating seal assembly (31) to the center. Set the assembly with the floating seal side up.
2) Install bearing (34).
2. Inner gear 1) Using tool J3, install floating seal (30) to the inside of inner gear (27).
3) Using tool J3, install floating seal (33) to retainer (32). Thinly apply grease (G2-LI) to the top of the floating seal. 2) Install retainer (29) to inner gear (27). 3) Using tool J4, install floating seal (28). Thinly apply grease (G2-LI) to the top of the floating seal.
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3. Outer gear 1) Using tool J4, install floating seal (26).
After installing, measure distance a between the end of retainer (29) and end of seal (28) at 4 points on the periphery. Check that the difference between the values at the 4 points does not exceed 1 mm.
After installing, measure distance b between the end of outer gear (5) and end of seal (26) at 4 points on the periphery. Check that the difference between the values at the 4 points does not exceed 1 mm.
4) Install inner gear (27). When installing the inner gear, match it to the retainer and floating seal assembly installed in Step 1-4). Take care not to damage the floating seal. Inner gear mounting bolt: 455 565 Nm {46.4 57.6 kgm}
2) Install oil seal (25). Apply grease to part P shown below. Part P: Grease (G2-LI)
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HD465-7, HD605-7
3) Install outer gear (5). Take care not to drop the floating seal from the bottom. Take care that the oil seal at the bottom will not be rolled up.
3) Install discs (21) and plates (22) alternately in order. Install the 12 discs and 11 plates. 4) Install damper (20). 4. Dampers, discs, plates, and spacer 1) Install bolts [3] to the sling taps, and then install spacer (24).
Install damper (20) with seat b (projected part: 4.5 mm thick) up. Install spacer (24) with the chamfered side down. 2) Install damper (23). Install damper (23) with seat a (projected part: 1 mm thick) down. If the damper is installed reversely, the disc will be worn abnormally. Accordingly, be sure to install it in the correct direction. If the damper is installed reversely, the disc will be worn abnormally. Accordingly, be sure to install it in the correct direction.
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5) Install plates (19).
3) Pass guide (14) through spring (13) and install them to the parking brake piston. 4) Using tool J2, compress spring (13) and install washer (12) from the underside of the brake piston. Pass pin (11) through guide (14) to fix the guide.
5. Assembly of parking brake assembly Since the installing load on the internal spring is large, assemble the assembly carefully according to the following procedure. 1) Install seal rings (17) and (18) to brake piston (16). Periphery of seal ring: Grease (G2-LI)
2) Install parking brake piston (15) to brake piston (16). Match the match marks made when the piston was removed.
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5) Install 30 springs (10) to cylinder (2). For the locations of the 8 single springs, see the distinction marks made when they were removed.
When installing the piston assembly, match it to dowel pin C.
6) Install seal rings (8) and (9) to cylinder (7). Periphery of seal ring: Grease (G2-LI)
8) Install guide bolt [2] and cylinder (7). Match the match marks made when the cylinder was removed. Match the faucet joint portion of cylinder (7) to that of cylinder (2) by hitting cylinder (7) evenly with a plastic hammer, etc.
7) Install piston assembly (3) to cylinder (2). Match the match marks made when the piston assembly was removed.
9) Tighten 13 cylinder mounting bolts (4) gradually and evenly to the specified torque. Mounting bolt: Adhesive (LT-2) Mounting bolt: 153 190 Nm {15.6 19.3 kgm}
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10) Apply hydraulic pressure to parking brake releasing port P (20 x 1.5) and check that the piston is pulled up and the parking brake works. Parking brake releasing pressure: 8.7 MPa {85 kg/cm2}
7. Using tool J1, fix outer gear (5) and wheel hub (6).
Fix outer gear (5) and wheel hub (6) at following points a , b , c , and d (4 places in total). 11) Tighten parking brake releasing bolts A (10 pieces) gradually and evenly.
6. Install parking brake assembly (1) to outer gear (5). Match the match marks made when the parking brake assembly was removed.
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FRONT SUSPENSION CYLINDER
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY

REMOVAL
1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Remove the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS ASSEMBLY. 3. Remove the wheel hub assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL HUB ASSEMBLY. 4. Release nitrogen gas. For details, see TESTING AND ADJUSTING, Testing and adjusting front suspension cylinder. 5. Disconnect hose (1). 9. Remove 4 bolts (8). 1) Revolve the knuckle arm toward the truck body about 40 degrees and remove the bolt marked with q. 2) Return the knuckle arm to its original position and jack up the king pin and remove the bolts marked with .
6. Disconnect tubes (2) and (3). 7. Pull out pin (4) and disconnect tie rod (5). 8. Pull out pin (6) and remove steering cylinder (7).
10. Using a forklift, etc., sling the front suspension cylinder assembly and pull out pin (9) on the rod side. 11. Disconnect and remove front suspension cylinder assembly (10) from the knuckle arm. Front suspension cylinder assembly: 500 kg
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INSTALLATION
Carry out installation in the reverse order to removal. k Never align the pin with the pin hole by starting the engine and operating the steering wheel. It is very dangerous. When aligning the pin and pin hole, disconnect the hoses on the head side and bottom side of the steering cylinder so that you can adjust the length of the steering cylinder rod. Use a lever block or a bar to align them. k Before operating the steering system after finishing installation, be sure to refill the front suspension cylinder with nitrogen gas and adjust it. For details, see TESTING AND ADJUSTING, Testing and adjusting front suspension cylinder.
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HD465-7, HD605-7
DISASSEMBLY AND ASSEMBLY OF FRONT SUSPENSION CYLINDER ASSEMBLY (Standard cylinder)

Special tools
2. Remove feed valve (1) and valve (2). 3. Removal of cylinder rod assembly. 1) Remove flange mounting bolts (3) and air bleeding valve (4). 2) Sling cylinder rod assembly (5), plate (6), retainer (7), and flange (8) together. 4. Disassembly of flange 1) Remove plate (6), retainer (7), and flange (8) from rod assembly (5). 2) Remove dust seal (9) and bushing (10) from retainer (7). 3) Remove U-packing (11) and bushing (12) from flange (8). 5. Remove wear ring (13) from cylinder rod (5).
792-103-4102 1 Q 2 790-101-5421 01010-81240 792-610-1000 792-610-1100 792-610-1200
Push tool Grip Bolt Suspension tool Pump assembly Charging tool
t t t t
1 1 1 1 1 1
DISASSEMBLY
Using a block, erect the cylinder assembly.
1. Cover Remove the dust cover.
Sketch
Part No.
Part name
Q'ty
HD465-7, HD605-7
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ASSEMBLY
(See the figure for disassembly, too.) 1. Installation of wear ring Install wear ring (13) to cylinder rod (5). Outside of wear ring: Engine oil (EO10-CD) 2. Assembly of flange 1) Using tool Q1, press fit bushing (12) to flange (8) and install U-packing (11). Inside of bushing: Engine oil (EO10-CD) a When installing the U-packing, check that there are 4 projections on the top of the inside lip.
2) Press fit bushing (10) to retainer (7) and install dust seal (9). a When press fitting the bushing, take care not to deform it. Periphery of seal: Adhesive (LT-2) 3. Assembly of cylinder rod assembly 1) Install flange (8), retainer (7), and plate (6) to the cylinder rod. Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.
a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent).
2) Using a block, erect the cylinder. a Fill the cylinder with engine oil. Cylinder: Approx. 16.5 (EO10-CD)
3) Sling cylinder rod assembly (5) and install it to the cylinder. a If the rod assembly is inserted too deep, the oil spouts out. Stop it to a position where the oil does not spout out. a After installing the front suspension assembly to the truck body, adjust the oil and gas, using tool Q2 . For details, see TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER. 4) Install flange (8), retainer (7), and plate (6) to the cylinder with bolts (3). Mounting bolt: 58.9 73.6 Nm {6.0 7.5 kgm}
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HD465-7, HD605-7
5) Install air bleeding valve (4). Valve: 39.2 49.0 Nm {4 5 kgm} 4. Install valve (2) and feed valve (1). Oil level valve and air intake valve: 39.2 49.0 Nm {4 5 kgm} 5. Cover Install the dust cover. a The dust cover consists of 2 pieces. Reduce the clearance between them to 0.5 mm or less.
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DISASSEMBLY AND ASSEMBLY OF FRONT SUSPENSION CYLINDER ASSEMBLY (Cylinder with buffer ring)
Special tools
2. Remove feed valve (1) and valve (2). 3. Removal of cylinder rod assembly. 1) Remove flange mounting bolts (3) and air bleeding valve (4). 2) Sling cylinder rod assembly (5), plate (6), retainer (7), and flange (8) together. 4. Disassembly of flange 1) Remove plate (6), retainer (7), and flange (8) from rod assembly (5). 2) Remove dust seal (9) and bushing (10) from retainer (7). 3) Remove U-packing (11), buffer ring (14) and bushing (12) from flange (8). 5. Remove wear ring (13) from cylinder rod (5).
792-103-4102 1 Q 2 790-101-5421 01010-81240 792-610-1000 792-610-1100 792-610-1200
t t t t
1 1 1 1 1 1
DISASSEMBLY
Using a block, erect the cylinder assembly.
1. Cover Remove the dust cover.
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Sketch
Part No.
Part name
Q'ty
HD465-7, HD605-7
FRONT SUSPENSION CYLINDER k Buffer ring (14) is made of 2 parts. When installing it, set the round corner of part [2] (Black) inside of part [1] (Blue). The side indicated by the arrow is the pressure side.
ASSEMBLY
(See the figure for disassembly, too.) 1. Installation of wear ring Install wear ring (13) to cylinder rod (5). 2 Outside of wear ring: Engine oil (EO10-CD) 2. Assembly of flange 1) Using tool Q1, press fit bushing (12) to flange (8) and install U-packing (11) and buffer ring (14). 2 Inside of bushing: Engine oil (EO10-CD) a When installing the U-packing, check that there are 4 projections on the top of the inside lip.
2) Press fit bushing (10) to retainer (7) and install dust seal (9). a When press fitting the bushing, take care not to deform it. 2 Periphery of seal: Adhesive (LT-2) 3. Assembly of cylinder rod assembly 1) Install flange (8), retainer (7), and plate (6) to the cylinder rod.
a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent).
2 Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.
2) Using a block, erect the cylinder. a Fill the cylinder with engine oil. 5 Cylinder: Approx. 16.5 l (EO10-CD)
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3) Sling cylinder rod assembly (5) and install it to the cylinder. a If the rod assembly is inserted too deep, the oil spouts out. Stop it to a position where the oil does not spout out. a After installing the front suspension assembly to the truck body, adjust the oil and gas, using tool Q2 . For details, see TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER. 4) Install flange (8), retainer (7), and plate (6) to the cylinder with bolts (3).
3 Mounting bolt: 58.9 73.6 Nm {6.0 7.5 kgm} 3 Valve: 39.2 49.0 Nm {4 5 kgm}
5) Install air bleeding valve (4).
4. Install valve (2) and feed valve (1).
3 Oil level valve and air intake valve: 39.2 49.0 Nm {4 5 kgm}
5. Cover Install the dust cover. a The dust cover consists of 2 pieces. Reduce the clearance between them to 0.5 mm or less.
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HD465-7, HD605-7
REAR SUSPENSION CYLINDER
REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative () terminal of the battery. 1. Release nitrogen gas. For details, see TESTING AND ADJUSTING, Testing and adjusting rear suspension cylinder. 2. Remove protector (1). 3. Using a forklift, etc., sling the rear suspension cylinder assembly and pull out pin (2) on the bottom side. 4. Pull out pin (3) on the rod side and remove rear suspension cylinder assembly (4). Rear suspension cylinder assembly: 180 kg
INSTALLATION
Carry out installation in the reverse order to removal. , When aligning the pin holes, never insert your fingers in them. # Refill the rear suspension cylinder with nitrogen gas and adjust it. For details, see TESTING AND ADJUSTING, Testing and adjusting rear suspension cylinder.
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HD465-7, HD605-7
DISASSEMBLY AND ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY (Standard cylinder)

Special tools
792-625-1300 1 Q 2 790-101-5421 01010-81240 792-610-1000 792-610-1100 792-610-1200
t t t t
1 1 1 1 1 1
Sketch
Part No.
Part name
Q'ty
DISASSEMBLY
1. Guard Sling the cylinder assembly and loosen clamp (1), and then unbutton and remove guard (2). 2. Drain oil from the cylinder. 3. Feed valve and valve Remove cover (3), feed valve (4), and valve (5).
5. Flange and retainer 1) Remove retainer (6) and flange (8) from cylinder rod assembly (7). 2) Remove U-packing (10), backup ring, and Oring (11) from flange (8). 3) Remove bushing (12) from flange (8). 4) Remove seal (13) and bushing (14) from retainer (6).
6. Wear ring Remove wear ring (15) from rod (16).
4. Cylinder rod assembly 1) Erect the cylinder assembly upside down. 2) Remove the mounting bolt of retainer (6). 3) Slowly sling and remove cylinder rod assembly (7), retainer (6), and flange (8) as 1 unit from cylinder (9) with a crane.
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ASSEMBLY
1. Wear ring Install wear ring (15) to rod (16).
3. Retainer 1) Using tool Q1, install bushing (14) to retainer (6). 2) Install seal (13) to retainer (6). Periphery of seal: Adhesive (LT-2)
2. Flange 1) Using tool Q1, install bushing (12) to flange (8). 2) Install U-packing (10) to flange (8). a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent). 3) Install backup ring and O-ring (11) to flange (8).
4. Cylinder rod assembly 1) Using a block, erect cylinder (9). 2) Sling cylinder rod assembly (7) and install it to cylinder (9). 3) Install flange (8) and retainer (6) to cylinder rod assembly (7). Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.
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DIFFERENTIAL
4) Install retainer (6) and flange (8) together to cylinder (9) with the mounting bolts. Mounting bolt: 98 123 Nm {10.0 12.5 kgm} 5. Air intake valve and oil level valve 1) Set the cylinder assembly upside down. 2) Sling the cylinder so that dimension D on its bottom side will be 140 3 mm.
6. Guard 1) Install guard (2) and secure it with clamp (1). Clamp: 6.8 0.49 Nm {69 5 kgcm}
3) Supply oil through the oil level port with the oil level pump and spout oil from the air intake port until bubbles do not come out any more. 4) After supplying oil, install level (5) and feed valve (4). Air intake valve and oil level: 39.2 49.0 Nm {4 5 kgm} 5) Install cover (3).
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DISASSEMBLY AND ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY (Cylinder with buffer ring)
Special tools
792-625-1300 1 Q 2 790-101-5421 01010-81240 792-610-1000 792-610-1100 792-610-1200
t t t t
1 1 1 1 1 1
Sketch
Part No.
Part name
Q'ty
DISASSEMBLY
1. Guard Sling the cylinder assembly and loosen clamp (1), and then unbutton and remove guard (2). 2. Drain oil from the cylinder. 3. Feed valve and valve Remove cover (3), feed valve (4), and valve (5).
5. Flange and retainer 1) Remove retainer (6) and flange (8) from cylinder rod assembly (7). 2) Remove U-packing (10), buffer ring (17), backup ring and O-ring (11) from flange (8). 3) Remove bushing (12) from flange (8). 4) Remove seal (13) and bushing (14) from retainer (6).
6. Wear ring Remove wear ring (15) from rod (16).
4. Cylinder rod assembly 1) Erect the cylinder assembly upside down. 2) Remove the mounting bolt of retainer (6). 3) Slowly sling and remove cylinder rod assembly (7), retainer (6), and flange (8) as 1 unit from cylinder (9) with a crane.
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HD465-7, HD605-7
ASSEMBLY
1. Wear ring Install wear ring (15) to rod (16).
2. Flange 1) Using tool Q1, install bushing (12) to flange (8). 2) Install U-packing (10) and buffer ring (17) to flange (8). a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent). k Buffer ring (17) is made of 2 parts. When installing it, set the round corner of part [2] (Black) inside of part [1] (Blue). 3) Install backup ring and O-ring (11) to flange (8).
3. Retainer 1) Using tool Q1, install bushing (14) to retainer (6). 2) Install seal (13) to retainer (6). 2 Periphery of seal: Adhesive (LT-2)
4. Cylinder rod assembly 1) Using a block, erect cylinder (9). 2) Sling cylinder rod assembly (7) and install it to cylinder (9). 3) Install flange (8) and retainer (6) to cylinder rod assembly (7).
2 Mating faces of flange and retainer: Gasket sealant (LG-6)
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a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.
5. Feed valve and valve 1) Set the cylinder assembly upside down. (Set the rod down.) 2) Sling the cylinder so that dimension D on the rod side will be as follows. When buffer ring is not installed: 140 3 mm When buffer ring is installed: 124 3 mm
3) Supply oil through the oil level port with the oil level pump and spout oil from the air intake port until bubbles do not come out any more. 4) After supplying oil, install level (5) and feed valve (4). 3 Air intake valve and oil level: 39.2 49.0 Nm {4 5 kgm} 5) Install cover (3).
4) Install retainer (6) and flange (8) together to cylinder (9) with the mounting bolts.
3 Mounting bolt: 98 123 Nm {10.0 12.5 kgm}
6. Guard 1) Install guard (2) and secure it with clamp (1).
3 Clamp: 6.8 0.49 Nm {69 5 kgcm}
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HD465-7, HD605-7
RETARDER COOLING PUMP
REMOVAL AND INSTALLATION OF RETARDER COOLING PUMP ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Disconnect tubes (1) and (2) and hose (3). a Prepare a pan to receive oil from the joints. 2. Remove retarder cooling pump assembly (4). Retarder cooling pump assembly: 30 kg
INSTALLATION
Carry out installation in the reverse order to removal. Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190 (EO30-CD or EO10W-CD) Hydraulic tank: 122 (EO10-CD)
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HD465-7, HD605-7
STEERING, HOIST, AND HOIST CONTROL PUMP
REMOVAL AND INSTALLATION OF STEERING, HOIST, AND HOIST CONTROL PUMP ASSEMBLY
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Disconnect tubes (1) and (2) and hoses (3), (4), and (5). a Prepare a pan to receive oil from the joints. 2. Remove steering, hoist and hoist control pump assembly (6). Steering, hoist and hoist control pump assembly: 35 kg
INSTALLATION
Carry out installation in the reverse order to removal. Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190 (EO30-CD or EO10W-CD) (EO10-CD) Hydraulic tank: 122
HD465-7, HD605-7
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(10)
TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP
REMOVAL AND INSTALLATION OF TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP ASSEMBLY
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Disconnect tubes (1), (2), and (3) and block (4). a Prepare a pan to receive oil from the joints. 2. Remove torque converter, transmission and retarder cooling, and brake pump assembly (5). Torque converter, transmission and retarder cooling, and brake pump assembly: 25 kg
INSTALLATION
Carry out installation in the reverse order to removal. Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190 (EO30-CD or EO10W-CD) (EO10-CD) Hydraulic tank: 122
30-120
(10)
HD465-7, HD605-7
STEERING VALVE
REMOVAL AND INSTALLATION OF STEERING VALVE ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. 1. Remove yoke fixing bolt (1). Fix yoke (2) to the upper part with ropes, etc. so that it will not come off the spline of the column shaft. 2. Remove cover (3). 3. Disconnect hoses (4), (5), (6), (7), and (8). 4. Remove steering valve assembly (9). Using ropes, etc., lift off the steering valve assembly.
INSTALLATION
Since the yoke fixing bolt has fine threads, do not apply excessive force to it to damage the threads.
HD465-7, HD605-7
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STEERING VALVE
DISASSEMBLY AMD ASSEMBLY OF STEERING VALVE ASSEMBLY

Securing of clean working condition 1. Cleanliness is essential to maintenance of the power steering system. The hydraulic circuit must be isolated from impurities. 2. When disassembling any part of the unit, prepare a clean worktable. 3. Before disconnecting a pipe, wipe off the external dirt from it. 4. Before placing the unit on the worktable, be sure to wipe off the external dirt from it. 5. After disassembling the unit, clean the parts in kerosene-based solvent free of impurities and dry them by blowing dry compressed air free of impurities against them. If any solvent other than the above is used, it can deteriorate the rubber seals. Never wipe the parts with cloths or blow steam against the unit. Since the solvent is combustible material, handle it carefully and keep it off fire.
DISASSEMBLY
1. Remove 7 mounting bolts (1). Insert a screwdriver between end cover assembly (2) and case (3) to remove end cover assembly (2). After removing the end cover assembly, check the edges of the end cover hole for breakage.
2. Remove commutator (5) and washer (6). Do not remove pin (4).
PREPARATION
1. Stop up the 5 ports of the valve body with plugs and clean the outside of the valve, and then remove the plugs. 2. Install tube nut [1] to one of the ports. 3. Install the valve body to vise [2] with the end cover up. Do not hold the valve body directly with the vise. If it is held so, the unit may be broken. Special tools
1 2
790-452-1200 790-452-1100
Pilot ring tool Tool installer set
1 1
30-122
Sketch
Part No.
Part name
Q'ty
HD465-7, HD605-7
STEERING VALVE
3. Using 2 mounting bolts (1), remove commutator ring (7) and manifold (8). 4. Using 2 mounting bolts (1), remove rotor assembly (9) and wear plate (10) similarly to the commutator ring and manifold.
9. Install valve body (11) to the vise with input shaft (18) up and make match marks A on upper case (19) and valve body (11). 10. Remove 4 mounting bolts (20) and raise input shaft (18) to remove input shaft, upper case, and valve spool assembly (23). The valve spool is fitted to the body with very narrow clearance between them. Accordingly, if it is pressed sideway, it cannot be pulled out completely. When removing it from the housing, never apply an excessive force to it.
5. Insert a screwdriver between case (3) and valve body (11) to remove case (3). 6. Remove drive link (12).
7. Remove ball (13). 8. Remove rod (14), roller (15), rod (16), and spring (17).
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STEERING VALVE
11. Remove upper case assembly (22) from input shaft and valve spool assembly (23), and then remove shim (24) and spacer (25). Check the thickness and quantity of the shims.
14. Using pin [3] ( 3.0 mm, = Min. 16 mm), remove needle roller (36) from input shaft (18). Perform this work on a wood block so that the input shaft will not be damaged.
12. Remove seal (26) and snap ring (27), and then remove spacer (28), ring (29A), seal (29), and seal ring (30) from upper case (19). Usually, seal (29) and seal ring (30) are in 1 unit.
15. Direct valve spool (37) down and remove torsion bar (38) and spacer (39) from the input shaft and valve spool assembly. Do not remove needle roller (40) from the torsion bar.
13. Remove snap ring (31), thrust washer (32), thrust bearing (33), thrust washer (34), and wave washer (35) from input shaft (18).
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STEERING VALVE
16. Direct valve spool (37) down and revolve input shaft (18) until drive link (41) comes off. 17. Direct valve spool (37) down and rotate input shaft (18) clockwise until ball (42) comes off. Since ball (42) may come off by itself, take care not to lose it.
ASSEMBLY
Before assembling, clean the parts in basedbased solvent free of impurities and dry them by blowing dry compressed against them. Never wipe them with cloths. Check the edges of the lapped surface for paint. Do not apply oil to the parts to be installed, unless otherwise specified. Replace the all seals with new ones. 1. Set thrust washer (34), thrust bearing (35), and thrust washer (32) in order to input shaft (18), and then install snap ring (31). Thrust washer (32) is larger than thrust washer (34).
Remove ball retaining spring (43) only when replacing it. When removing it, hold its flat end with priers and raise it until it is removed from valve spool (37). Take care not to damage the periphery of the valve spool and control edge.
2. Install wave washer (35) to thrust bearing (33) and thrust washer (34). 3. Install ball (42) to inside of valve spool (37).
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STEERING VALVE
4. Insert input shaft (18) in valve spool (37), rotating it counterclockwise so that the ball will be fitted to its groove. Keep the spool horizontally during this work.
6. Check the splines of drive link (41) and input shaft (18), and then install drive link (41), matching the spline of valve spool (37).
5. Set the intermediate part of torsion bar (38) between thrust washer (34) and valve spool (37). If the torsion bar is set as above, the valve spool and input shaft is positioned.
If the splines of the drive link and input shaft are not meshed with each other, rotate the input shaft a little to mesh them, and then insert the drive link. Set the torsion bar securely. Rotate the input shaft in the spool projecting direction (clockwise) until it stops. If the drive link is installed correctly, a clearance of 8 9 mm is made between the thrust washer and valve spool.
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STEERING VALVE
7. Measure diameter of needle roller (40) of torsion bar (38) at several points. Check that the difference between measured diameters does not exceed 0.025 mm. 8. Set spacer (39) to torsion bar (38) and insert them in valve spool and input shaft assembly (23).
11. Install spacer (25) to the input shaft and valve spool. When installing the spacer, direct lip surface "B" in it toward washer (35). 12. Install input shaft and valve spool assembly (23) to valve body (11). The valve spool is fitted to the body with very narrow clearance between them. Accordingly, if it is pressed sideway when installed, it may not operate normally. 13. Set shim (24) on thrust washer (32). Apply grease to new seal (19B) and fix it to the groove of upper case (19). Install upper case (19), matching match marks A, and tighten mounting bolts (20) lightly.
9. Using pin [3] (Outside diameter: 3 mm), align the pin holes of torsion bar (38) and input shaft (18). 10. Using pin [3], drive needle roller (36) in input shaft to a depth of 0.8 mm. Check that needle roller (36) is not projected from the inspection sheet.
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STEERING VALVE
14. Set tool T1 so that the valve body will be aligned with the upper case.
17. Pull down and fix input shaft (18) and mesh drive link (12) with the spline of the valve spool, and then rotate the spool so that its end will be flush with the valve body. 18. Remove drive link (12) again and adjust its position so that needle roller (40) of the torsion bar will be in its groove. Then, insert drive link (12) in spool (37).
15. Tighten 4 upper case mounting bolts and remove tool T1. Mounting bolt: 24.40 29.80 Nm {2.49 3.04 kgm} Install the valve body to a vise with the input shaft down. 16. Measure groove width of drive link (12) at several points over the length and check that the difference between the obtained values does not exceed 0.025 mm. 19. Using depth gauge [4], measure fitting height h of the valve spool above the valve body.
If fitting height h is below 0.063 mm, do not adjust the shim. If fitting height h is larger than 0.063 mm, adjust the shim by repeating Steps 12 19 so that h will be below 0.063 mm.
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STEERING VALVE
20. Install ball (13). 21. Set rod (16) to spring (17) and install them to valve body (11). Then, install roller (15) and rod (14).
23. Lubricate a new seal and the seal groove with grease and install ring (11A) and seal (11B) to valve body (11) in order.
22. Before installing the rotor, check it according to the following procedure. 1) Set end cover assembly (2) with the pin side up and set rotor assembly (9) with the rotor spline side down, and then check that the rotor rotates freely in the stator.
24. Using guide pin [6], install wear plate (10), rotor assembly (9), manifold (8), and commutator ring (7).
2) Measure thickness of rotor A and that of stator B at several points and check that the each difference between them is below 0.18 mm. 3) Using filler gauge [5], the clearance between stator B and rotor A is below 0.18 mm.
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STEERING VALVE
25. Lubricate the inside of both ends of case (3) and the seal installed to valve body (11) with grease. 26. Install case (3) to valve body (11). a Install end cover (2) to the end of the case and tighten the mounting bolts (1) evenly so that the case will be inserted straight. 27. Remove end cover (2) and lubricate a new seal and the seal groove with grease, and then install ring (2A) and seal (2B) to the end cover in order.
a Set the oval hole of the commutator and one of the bolt holes of the end cover assembly in line.
29. Rotate the input shaft so that the end of drive link (12) will be inserted in the oval hole of the commutator. a Lubricate the seal in the end cover with grease. 30. Set end cover assembly (2) on cover (3) and tighten the 5 mounting bolts evenly. 28. Apply grease to end cover assembly (2) and fit washer (6) and commutator (5) so that they will not fall even if they are set down. a Install the commutator so that its hollow C will be on the end cover assembly side. Mounting bolt: 61.0 74.5 Nm {6.22 7.6 kgm} a Tighten the mounting bolts in the diagonal order so that the sleeve and end cover will not slant while they are being installed. 31. Remove guide pin [6] and tighten the remaining 2 bolts evenly. Mounting bolt: 61.0 74.5 Nm {6.22 7.6 kgm}
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STEERING VALVE
32. Direct the input side up and wind tapes onto the serrated part. Seal (26), spacer (28), ring (29A), seal (29), and seal ring (30) are the parts of a kit. Seal (29) and seal ring (30) have been installed as 1 unit.
33. Apply grease to the inside and outside of seal (29) and seal ring 30 and install them with the lip side in the valve. 34. Install ring (29A). 35. Using tool T2, install spacer (28) from the small diameter end.
36. Install snap ring (27) with its rounded side in the valve. 37. Install seal (26) to the upper case. When installing seal (26), apply grease to its inside and outside.
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DEMAND VALVE
REMOVAL AND INSTALLATION OF DEMAND VALVE ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Drain hydraulic oil. Hydraulic tank: 122 2. Disconnect tubes (1), (2), (3), and (4). 3. Remove demand valve assembly (5). Demand valve assembly: 30 kg
INSTALLATION
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic tank: 122 (EO10-CD)
Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder (for steering).
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HD465-7, HD605-7
HOIST VALVE
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY

REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Drain hydraulic oil. Hydraulic tank: 122 2. Disconnect the tube and hose from the underside of hoist valve assembly (1). 3. Disconnect tubes (2), (3), and (4) and hose (5). 4. Hoist valve assembly (1). Hoist valve assembly: 35 kg
INSTALLATION
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic tank: 122 (EO10-CD)
HD465-7, HD605-7
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STEERING CYLINDER
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY

Special tools
1 2 3
790-502-1003 790-101-1102 790-102-3802 790-302-1270 790-201-1702
Repair stand Hydraulic pump Wrench assembly Socket Push tool kit Push tool Grip Bolt Push tool kit Push tool Grip Bolt Expander Ring Clamp
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Sketch
Part No.
Part name
Q'ty
4. Remove cylinder (4) from tool U1. 5. Disassembly of piston rod assembly 1) Set tool U1 to piston rod assembly (3). 2) Using tool U3, remove nut (5). Width across flats of nut: 50 mm
4 U
790-101-1771 790-101-5021 01010-50816 790-201-1500
790-101-1580 790-101-5021 01010-50816
6 7 8
790-720-1000 796-720-1650 07281-01029
DISASSEMBLY
1. Set cylinder assembly (1) to tool U1. 2. Raise the lock of the cylinder head nut. Using tool U2, remove cylinder head assembly (2). 3) Remove piston assembly (6) and cylinder head assembly (7) from rod (8).
3. Pull cylinder head and piston rod assembly (3) out of cylinder (4). Prepare a container to receive oil which flows out when the piston rod assembly is pulled out of the cylinder.
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HD465-7, HD605-7
STEERING CYLINDER
6. Disassembly of piston assembly 1) Remove wear ring (9) from piston (10). 2) Remove piston ring (11) from piston (10).
ASSEMBLY
Apply engine oil to the sliding surfaces of each part. When assembling, take care not damage the packing, dust seal, and O-ring. 1. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (15) to cylinder head (16). When press fitting the bushing, take extreme care not to deform it. 2) Install rod packing (14). Install the rod packing as shown in the following figure. 3) Install backup ring (18) and O-ring (17) in order. Do not install the backup ring forcibly. Warm it in water at 50 60C before installing it. 4) Using tool U5, install dust seal (13) to cylinder head (16), and then install snap ring (12).
7. Disassembly of cylinder head assembly 1) Remove snap ring (12) and dust seal (13). 2) Remove rod packing (14). 3) Remove bushing (15) from cylinder head (16). 4) Remove O-ring (17) and backup ring (18).
2. Assembly of piston assembly 1) Using tool U6, expand piston ring (11). Set the piston ring to the tool and rotate the handle 8 10 turns to expand the piston ring. 2) Remove the piston ring from the tool and install it to piston (10).
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STEERING CYLINDER
3) Set tool U7. Using tool U8, shrink the piston ring.
3) Remove piston rod assembly (3) from tool U1.
4) Install wear ring (9).
4. Set the cylinder to tool U1. 5. Install cylinder head and piston rod assembly (3) to cylinder (4).
3. Assembly of piston rod assembly 1) Install cylinder head assembly (7) and piston assembly (6) to piston rod (8). 6. Using tool U2, tighten cylinder head assembly (2). Cylinder head nut: 637.5 63.7 Nm {65 6.5 kgm}
2) Using tool U3, tighten nut (5). Nut: Adhesive (Loctite No. 262) Nut: 1,078.8 107.9 Nm {110 11.0 kgm} Width across flats of nut: 50 mm
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HD465-7, HD605-7
HOIST CYLINDER
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY

Special tools
790-502-1003 1 790-101-1102 2 3 4 5 790-102-3802 790-720-1000 796-720-1680 07281-01580 792-201-7310 790-101-5421 01010-81240 6 U 790-201-1851 790-101-5021 01010-50816 792-201-7410 790-101-5021 01010-80816 7 790-201-1500 790-201-1660 790-201-5021 01010-50816 790-201-1702
Repair stand Hydraulic pump Wrench assembly Expander Ring (For cylinder Clamp (For cylinder Push tool (For cylinder ) )
) ) ) ) ) )
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Sketch
Part No.
Part name
Q'ty
3. Remove cylinder cylinder (2).
and rod assembly (3) from
Grip (For cylinder Bolt (For cylinder Push tool (For cylinder ) Push tool (For cylinder ) Grip (For cylinder ) Bolt (For cylinder ) Plate (For cylinder Grip (For cylinder Bolt (For cylinder Push tool kit (For cylinder ) Plate (For cylinder ) Grip (For cylinder ) Bolt (For cylinder )
4. Remove piston nut (4) and lift down rod (6) from cylinder (5). 5. Pull cylinder assembly (1) out of rod (6).
DISASSEMBLY
When disassembling, take care not to damage the rod packing, dust seal, piston ring, wear ring, etc.
1. Set the cylinder assembly to tool U1. 2. Using tool U2, remove cylinder head assembly (1) from cylinde (2).
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HOIST CYLINDER
6. Disassembly of cylinder head assembly 1) Remove snap ring (7) and dust seal (8) from cylinder head assembly (1). 2) Remove rod packing (9) and bushing (10). 3) Remove backup ring (11) and O-ring (12).
ASSEMBLY
Check each part for dirt, flaw, etc. and apply engine oil to the sliding surfaces before assembling. 1. Using tool U6, press fit bushing (21) to cylinder (5).
7. Disassembly of piston assembly and cylinder 1) Remove wear ring (13). 2) Remove snap ring (14) and pull out piston assembly (15). 3) Remove piston ring (16) and wear ring (17) from piston assembly (15). 4) Remove snap ring (18) from cylinder (5), and then remove dust seal (19). 5) Remove rod packing (20) and bushing (21).
2. Install rod packing (20) to cylinder (5). Install the rod packing as shown in the following figure. 3. Using too U7, install dust seal (19).
4. Install snap ring (18).
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HD465-7, HD605-7
HOIST CYLINDER
5. Assembly of piston assembly 1) Using tool U3, expand piston ring (16) and install it to piston (15). Set the piston ring to tool U3 and rotate the handle 8 10 turns to expand the piston ring. 2) Set tool U4. Using tool U5, shrink piston ring (16).
7. Install wear ring (13) to cylinder
(5).
8. Assembly of cylinder head assembly 1) Using tool U6, press fit bushing (10).
3) Install wear ring (17).
9. Install rod packing (9) to cylinder head (1). Install the rod packing as shown in the following figure.
6. Install piston assembly (15) to cylinder and then install snap ring (14).
(5),
HD465-7, HD605-7
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HOIST CYLINDER
10. Using tool U7, install dust seal (8).
11. Install snap ring (7), O-ring (12), and backup ring (11).
15. Install cylinder der (2).
and rod assembly (3) to cylin-
12. Install head assembly (1) to rod (6). 13. Sling rod (6) and install it to cylinder (5). Align the bolt holes of the piston assembly and rod. 14. Tighten piston mounting nut (4). Degrease the fitting parts of the bolt and nut sufficiently. Width across flats of bolt: 24 mm Threads of piston rod: Adhesive (Loctite No. 262) Mounting nut: 274 27.4 Nm {28 2.8 kgm}
16. Using tool U2, tighten cylinder head assembly (1). Cylinder head assembly: 1,569.1 156.9 Nm {160 16 kgm}
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HD465-7, HD605-7
DUMP BODY
REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY

Special tools
5. Lift off dump body assembly (5). Dump body assembly HD465-7: 10,750 kg HD605-7: 13.450 kg
V1
790-441-1320
Hook
REMOVAL
Stop the truck on level ground and set the parking brake switch to the PARK position, then put blocks under the wheels. 1. Using tool V1, sling the dump body assembly temporarily by 4 points. 2. Remove hoist cylinder bottom pin (1) and fix it with a lever block, etc. so that hoist cylinder (2) will not fall down.
3. Disconnect body positioner rod (3) from the body. 4. Remove body hinge pins (4) on both sides. a Check the thickness, quantity, and location of the shims.
Sketch
Part No.
Part name
Q'ty
HD465-7, HD605-7
30-141
(10)
DUMP BODY
INSTALLATION
When aligning the pin holes, never insert your fingers in them. Bottom pin: 157 196 Nm {16 30 kgm}
Adjust the body positioner sensor. For details, see TESTING AND ADJUSTING, Adjusting body positioner sensor.
Install the shims as removed. When aligning the pin holes, never insert your fingers in them. Hinge pin: 245 309 Nm {25 31.5 kgm}
After installing the dump body assembly, deviation z of the dump body assembly from the cab assembly is in the following range. Standard range of dimension z: 58 12 mm
1. Adjust the shim of the dump body bottom mount. 1) Insert spacer 29 mm thick [1] at the end of dump body (5) (1 each on both sides). 2) Measure clearance x between the center of installing part of bottom mount (6) and top of rear frame (7). Measure the clearance at parts A, B, and C, 6 parts in total on both sides. 3) Calculate the respective shim thicknesses for 6 parts of A, B, and C on both sides. Shim thickness = (x 26) mm 4) Set shims (8) calculated in 3) above to the bottom mount (6). Standard shim thickness: 3 mm Thicknesses of shims: 1 mm, 3.2 mm 5) Remove spacer [1] and lower the dump body and check that the all 6 parts of A, B, and C of the bottom mount are in contact with the top of the rear frame.
If dimension z is out of the standard range, adjust it with shims (11) of body hinge pins on both sides. Thicknesses of shims: 1 mm, 6 mm
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HD465-7, HD605-7
DUMP BODY
2. After adjusting the shims on the bottom mount, adjust the shims on the left front mount. 1) Lower the dump body and measure thickness Y of pad (9). Standard thickness Y : 50 mm 2) If the pad thickness exceeds 50 mm or there is a clearance between the dump body and pad, add shim (10) to adjust the pad thickness properly.
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!
OPERATOR'S SEAT
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY

! The procedure for disassembling and assembling the operator's seat assembly (air suspension (ISRING HAUSEN)) is shown below.
A: B: C: D:
Headrest Seatback Seat cushion Right-hand armrest
E : Left-hand armrest F : Suspension cover G : Rails
DISASSEMBLY
1. Headrest 1) Referring to the figure, check the positions of the 2 clips (2) of headrest stay (1) on both sides.
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OPERATOR'S SEAT
2) Apply force b to part a of each clip (2) in the direction of the arrow to turn the clip. Release headrest stay (1) from part d of the clip and pull out up headrest (3).
2. Seatback 1) Disconnect 3 air hoses (5) from the rear left of seatback (4). Before disconnecting the air hoses, check their types.
2) Remove seatback hinge mounting bolt (6) (M8 bolt).
Pushing in both clips (2) simultaneously, remove headrest (3). 3) Bring seatback (4) down forward.
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OPERATOR'S SEAT
4) Apply force E to the right side of seatback (4) in the direction of the arrow. 5) Applying the force to seatback (4), pull its right side up. 6) Slide seatback (4) sideway and remove it.
2) Push cushion stopper wire (9) down with screwdriver [1], etc. 3) Pull out seat cushion (8) forward and remove it.
3. Seat cushion 1) Push cushion adjuster lever (7) inward and slide seat cushion (8) to the front end.
4. Armrest The procedure for disassembling right-hand armrest (10) is shown below. (Disassemble lefthand armrest (11) similarly.)
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OPERATOR'S SEAT
1) Remove plastic cap (12) from the armrest hinge. a Use a flat-head screwdriver, etc. to remove the cap. 2) Loosen armrest hinge mounting bolt (13).
6) Remove right-hand armrest (10). a There are 2 position adjustment washers (16) installed to each bolt between the armrest and seatback. Take care not to lose them.
3) Remove plastic cap (14), and then remove lower mounting bolt (15A) (M8 bolt) of righthand armrest (10).
5. Suspension cover 1) Remove right-hand hinge cover (17). 2) Remove plastic plate (18) from the rear with screwdriver [1], etc. a Take care not to damage the plastic plate by prying it off forcibly with a screwdriver, etc.
4) Turn right-hand armrest (10) up by 180 degrees. a If the armrest is not turned, you cannot apply the tool to upper mounting bolt (15B). 5) Remove plastic cap (14) and upper mounting bolt (15B)
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OPERATOR'S SEAT
3) Remove 4 suspension cover fixing rings (19).
6) Remove 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small) (25): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large) (26): Front lower part; 2 places 7) Remove suspension cover (27). a If you remove the suspension cover without performing the work in steps 5) and 6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear fixing plate (21), 2 cushion rails (22), and 4 bushings (23).
6. Rails 1) Turn over the seat assembly to set rails (28) on the upside.
5) Remove 3 metallic suspension cover clips (24).
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OPERATOR'S SEAT
2) Slide rails (28) to the rear end. 3) Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the front part of each rail.
ASSEMBLY
1. Skide rails 1) Put height adjustment washers (31) between slide rails (28) and suspension, and then set slide rails (28) in position.
4) Slide rails (28) to the front end. 5) Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the rear part of each rail, and then remove rails (28).
2) Set slide rails (28) to the front end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each slide rail. Hexagon socket head bolt: 21.4 27.6 Nm {2.18 2.82 kgm}
a Take care not to lose height adjustment washers (31) between the rails and suspension.
3) Set slide rails (28) to the rear end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each slide rail. Hexagon socket head bolt: 21.4 27.6 Nm {2.18 2.82 kgm}
HD465-7, HD605-7
30-149
(10)
OPERATOR'S SEAT
2. Suspension cover 1) Set suspension cover (27) in position and install 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small) (25): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large) (26): Front lower part; 2 places
3) Set 4 bushings (23) and 2 cushion rails (22), and then install cushion rear fixing plate (21), and 4 mounting bolts (20). Cushion rail mounting bolt: 21.4 27.6 Nm {2.18 2.82 kgm}
4) Install 4 suspension cover fixing rings (19).
2) Install 3 metallic suspension cover clips (24).
5) Install plastic plate (18) to the rear. 6) Install right-hand hinge cover (17).
30-150
(4)
HD465-7, HD605-7
OPERATOR'S SEAT
3. Armrest The procedure for assembling right-hand armrest (10) is shown below. (Assemble left-hand armrest (11) similarly.)
6) Tighten armrest hinge mounting bolt (13). a Tighten the bolt so that the arm will move smoothly. Operating effort at armrest end: 49 78.4 N {5 8 kg} 7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for each bolt and set right-hand armrest (10) in position.
4. Seat cushion 1) Slide in the seat cushion from the front of the fitting position. a If seat cushion (8) is slid to the rear, it is locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly and turn armrest (10) by 180 degrees. 3) Tighten upper mounting bolt (15B) lightly. 4) Tighten lower mounting bolt (15A) and upper mounting bolt (15A) permanently. Upper and lower armrest mounting bolt: 21.4 27.6 Nm {2.18 2.82 kgm} 5) Install 2 plastic caps (14).
HD465-7, HD605-7
30-151
(4)
OPERATOR'S SEAT
5. Seatback 1) Insert the left side of seatback (4), and then lower and set the right side.
3) Connect 3 air hoses (5) to the rear left of the seatback (4).
6. Headrest 1) Insert headrest (3) in seatback (4). a Check that 2 clips (2) on both sides are locked securely.
2) Install seatback hinge mounting bolt (6). Seatback hinge mounting bolt: 21.4 27.6 Nm {2.18 2.82 kgm}
30-152
(10)
HD465-7, HD605-7
90 OTHERS
Power train hydraulic circuit diagram ....................................................90- 2 Steering and hoist hydraulic circuit diagram..........................................90- 3 Brake hydraulic circuit diagram .............................................................90- 5 Electrical circuit diagram (1/6) ...............................................................90- 7 Electrical circuit diagram (2/6) ...............................................................90- 9 Electrical circuit diagram (3/6) ...............................................................90-11 Electrical circuit diagram (4/6) ...............................................................90-13 Electrical circuit diagram (5/6) ...............................................................90-15 Electrical circuit diagram (6/6) ...............................................................90-17 Electrical system diagram related to transmission control ....................90-19 Electrical system diagram related to monitor ........................................90-21 Electrical circuit diagram (A1 size) (1/2)................................................90-23 Electrical circuit diagram (A1 size) (2/2)................................................90-25 Electrical system diagram related to ABS controller ......................... 90-26-1 Electrical circuit diagram related to ABS ........................................... 90-26-3 Connectors table (A1 size) ....................................................................90-27 Arrangement drawing (A1 size).............................................................90-29
HD465-7, HD605-7
90-1
(12)
OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2
HD465-7, HD605-7
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
*1 EMERGENCY STEERING FLOW SWITCH HD465-7 Serial No.: 7001 7151 HD605-7 Serial No.: 7001 7059 *2 EMERGENCY STEERING OIL PRESSURE SWITCH HD465-7 Serial No.: 7152 and up HD605-7 Serial No.: 7060 and up HD465-7, HD605-7
90-3
(12)
BRAKE HYDRAULIC CIRCUIT DIAGRAM
*1 HD465-7 Serial No.: 7266 and up HD605-7 Serial No.: 7113 and up
HD465-7, HD605-7
90-5
(12)
ELECTRICAL CIRCUIT DIAGRAM (1/6)
HD465-7, HD605-7
90-7
HD465-7, HD605-7
90-9
HD465-7, HD605-7
90-11
HD465-7, HD605-7
90-13
HD465-7, HD605-7
90-15
HD465-7, HD605-7
90-17
HD465-7, HD605-7
90-19
(7)
HD465-7, HD605-7
90-21
(7)
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (1/2)
HD465, 605-7
HD465, 605-7
HD465-7, HD605-7
90-23
HD465, 605-7
HD465, 605-7
HD465-7, HD605-7
90-25
ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER
ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER HD465-7, HD605-7
HD465-7, HD605-7
90-26-1
(12)
ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS
ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS HD465-7, HD605-7
HD465-7, HD605-7
90-26-3
(12)
CONNECTORS TABLE (A1 SIZE)

ABS control related
Connector No. 01 02 03 04 05 06 07 08 11 12 12 13 14 15 16 17 18 20 21 22 23 1939 A A A1 A2 AAPR ABS AC1 ACBM ACCF ACCR ACM1 ACM2 ACM3 ACP1 ACP2 ACPS ACR1 ACR2 ACR3 ACR4 ACR5 ACRE ACTH AISS ARC ARSC AS1 AS2 ASR ASR1 ASR2 ASR3 ASR4 ASR5 ASR6 ASR7 ASS ATC1 ATC2 ATC3A ATC3B ATC4 ATC5A ATC5B ATC6 B01 B02 B03 B04 B05 B06 B07 B1 B1 B10 B11 B2 B2 B3 B3 BCOM BK BL BLS BR BRC1 BRC2 BRC3A BRC3B BRC4 BRC5A BRC5B BRC6 BT BT1 BT2 BT3 BT4 Type of connector Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal KES0 Terminal Terminal Terminal Terminal Terminal Terminal HD30 One-pin connector One-pin connector M M PACKARD M One-pin connector YAZAKI DT-T DT-T AMP AMP AMP AMP AMP SUMITOMO Relay Relay Relay Relay Relay AMP YAZAKI M M M SWP X M DT-T-T DT-T-T DT-T-T DT-T-T DT-T DT-T DT-T DT-T MIC MIC AMP040 AMP040 AMP040 AMP040 AMP040 X DT-T DT-T DT-T Terminal Terminal Terminal DT-T One-pin connector One-pin connector Terminal Terminal One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector DT-T (Gray) One-pin connector M One-pin connector MIC MIC AMP040 AMP040 AMP040 AMP040 AMP040 X DT Number of pin 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 9 1 1 1 1 3 6 1 2 3 3 5 5 5 16 12 2 4 4 4 4 4 4 2 6 3 6 6 3 6 2 2 2 2 2 2 2 2 17 21 20 16 12 20 16 4 6 6 6 1 1 1 3 1 1 1 1 1 1 1 1 1 8 1 6 1 17 21 20 16 12 20 16 4 6 Battery relay (B) Battery relay (M) Battery relay (B) Battery relay (M) Emergency steering relay (B) Emergency steering relay (M) Emergency steering relay (B) Emergency steering relay (M) Battery relay (E) Battery relay (BR) Washer tank motor Battery relay (E) Battery relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Circuit breaker Circuit breaker Circuit breaker Circuit breaker Connector for connecting J1939 device Lamp (Optional for payload meter) Lamp (Optional for payload meter) Emergency reset connector Emergency reset connector Air pressure sensor ABS system switch Air conditioner wiring harness Air conditioner blower motor ACC oil pressure sensor (Front) ACC oil pressure sensor (Rear) Temperature regulation servomotor Air outlet mode selection servomotor Recirculated/Fresh air selection servomotor Air conditioner control panel Air conditioner control panel Air conditioner pressure switch Blower main relay Blower Hi relay Blower M2 relay Blower M1 relay Compressor clutch relay Air conditioner blower resistor Thermistor AISS switch ARSC set switch ARSC system switch Acceleration sensor Acceleration sensor ASR system switch Steering angle sensor Shut off valve ASR valve (R) ASR valve (L) ASR oil pressure switch (R) ASR oil pressure switch (L) ASR oil ptessure switch (Main) Air suspension seat Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Software rewriting connector (Transmission controller) Intermediate connector Intermediate connector Winker lamp, stop lamp, tail lamp Backup lamp Backup alarm buzzer Backup alarm buzzer Body position sensor Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Grounding Grounding Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Beacon lamp Intermediate connector Intermediate connector Rotary lamp switch (If equipped) Air conditioner wiring harness Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Software rewriting connector (Retarder controller) Intermediate connector Fuse box Fuse box Fuse box Fuse box Location Address B9 B9 B9 B9 A8 A8 A8 A9 B8 B8 C8 C8 A8 A7 B7 B7 A9 A9 A9 B9 X6 V8 AH5 O2 M3 T2 L4 K3 V3 M6 W3 O7 O7 U2 W3 W4 W4 W4 W4 U2 U3 M3 P8 N3 N2 O2 O2 C2 L2 K3 L3 K3 L2 K1 T2 Z1 Z1 Z4 Z4 AA4 AA1 AA4 W4 K9 K8 J9 J9 J9 J9 K9 K8 L8 T9 F9 C7 N1 M4 Y2 Y2 Y4 Y4 Z4 Y1 Y2 S9 C9 X5 X7 X6 X6 Connector No. BZ2 CAB1 CAB2 CAN CAN1 CAN2 CG1 CG2 CH1 CH2 CJA CJB CJB CJC CJD CJE2 CJE3 CJH1 CJH2 CJK CJL CJN CJP CJP1 CJP2 CJPR CJS CJSL CJT CJT1 CJT2 CJW CK1 CLTP CM CN3 CN4 CN5 CN6 CN7 CN8 CN9 CN10 CN11 CN12 CN13 CN14 CN15 CN16 CN17 CN18 CN19 CN20 CN21 CN22 CN23 CN24 CNS1 CNS2 CNS3 COM D01 D02 D03 D04 D05 D07 D08 DL DPC1 DPC2A DPC2B DPC3A DPC4 DPC6 DPC7 DSL DSR DT7 DT8 E E01 E02A E02B E03 E04 E05 E06 E07 E08 E09 E10 E11A E11B E12A E12B E13A E13B E15 E16A Type of connector M DT-T (Gray) DT-T (Black) DT DT-T DT-T One-pin connector S S DT-T DT-T (Black) DT-T DT-T DT DT-T DT-T (Black) DT-T (Black) DT-T DT DT-T DT (Black) DT-T DT-T DT-T DT-T DT-T DT-T DT (Black) DT-T (Black) DT-T DT-T YAZAKI PACKARD DT-T (Green) DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T (Brown) DT-T (Green) DT-T (Black) One-pin connector DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T (Black) AMP070 AMP070 AMP070 AMP070 AMP070 AMP040 X DT-T DT-T Terminal Terminal DT-T DT-T DT-T DT-T Terminal Terminal DT-T DT-T Terminal Terminal Terminal Terminal Terminal Terminal DTHD (#4) DTHD (#4) Terminal Terminal Number of pin 2 8 8 3 3 3 1 1 8 8 6 8 6 6 6 6 8 8 6 6 6 8 6 6 6 6 6 6 8 8 6 6 6 2 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 2 12 12 12 1 2 2 2 2 2 2 2 12 20 18 12 18 12 8 4 1 1 12 4 1 1 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 Buzzer Intermediate connector Intermediate connector CAN connector VHMS CAN connector Resistor Cigarette lighter Cigarette lighter Machine monitor mode selector switch 1 Machine monitor mode selector switch 2 Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Bulb breakage check switch Coolant temperature sensor Lighting switch, passing switch, turn switch Input shaft speed sensor Intermediate shaft speed sensor Output shaft speed sensor Solenoid for transmission 1st clutch Fill switch for transmission 1st clutch Solenoid for transmission 2nd clutch Fill switch for transmission 2nd clutch Solenoid for transmission R clutch Fill switch for transmission R clutch Solenoid for transmission 3rd clutch Fill switch for transmission 3rd clutch Solenoid for transmission 4th clutch Fill switch for transmission 4th clutch Solenoid for transmission L clutch Fill switch for transmission L clutch Solenoid for transmission H clutch Fill switch for transmission H clutch Solenoid for torque converter lockup clutch Fill switch for torque converter lockup clutch Torque converter intermediate pressure sensor Torque converter oil temperature sensor Transmission valve oil temperature sensor Intermediate connector (Power window switch) Intermediate connector (Gear shift lever) Intermediate connector (Parking brake switch) Air conditioner wiring harness Diode Diode Diode Diode Diode Diode Diode Intermediate connector Machine monitor Machine monitor Machine monitor Machine monitor Machine monitor Machine monitor Software rewriting connector (Machine monitor) Door switch (Left) Door switch (Right) Intermediate connector Intermediate connector Emergency steering motor Alternator Starting motor Starting motor Engine speed sensor Oil level switch (If equipped) Oil filter switch Alternator Compressor Diode Alternator Grounding Heater relay Ribbon heater Heater relay Ribbon heater Intermediate connector Intermediate connector Grounding Grounding AE7 AH1 AH1 AF1 AH5 C2 AE6, AF1 AF8 AG9 AE6 AG9 AJ9 AH9 AJ9 AG9 AG1 AG1 AI2 AI9 M3 W8 W8 W8 M6 V8 P2 W8 X6 P8 P1 P1 P8 Q1 O7 N3 F1 T2 T2 J2 M2 AE8 Q8 AC9 AC9 AD7 AB9 AB9 AB9 AA9 AA9 AA9 AA9 AA9 AA9 Z9 Z8 Z8 Y8 Y7 Z8 Z8 Z5 AA5 AC5 Location Address R1 Q9 Q9 AJ6 T9 Q1 M5 M5 M1 M1 D8 B7 E8 D8 D8 AI9 A12 B8 L7 J3 I9 H9 I9 C8 L7 I9 L8 L7 H9 Connector No. E16B E17A E17B E2B ECM A ECM B EG4 ENG ER ER1 ER2 ER3 FBC FL01 FL04 FL05 FLB FLL FLTP FOG FR01 FS2 FS3 FS4 FS5 FS8 FSOFSO+ FUA FUB G G G21 GND H01 H10 H20 HAZ HEAT HEPC HES HN HN1A HN1B HN2A HN2B HSL HSL HSOL HTA HTB IMPR IMTP J01 J02 J03 J04 J05 J07 J08 J09 J10 JC01 JC02 JC03 JC04 JC11 JC12 JC13 JC14 JC15 JCA JCB JCC JCD JCE JCF JCG JT1 JT2 LINK LKO LKO LP LS M MON1 MON2 MON3 MS11 MS12 MS21 MS22 MS31 MS32 OLPR OP1 OP2 OP3 OP4 Type of connector Terminal DT-T DT-T DT DRC26 DRC26 DT-T (Brown) DT-T (Gray) Terminal Terminal Terminal Terminal M DT-T YAZAKI DT-T PACKARD M DT-T One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector Terminal Terminal Terminal Terminal One-pin connector One-pin connector Terminal Terminal DT-T One-pin connector One-pin connector M DT DT-T Terminal One-pin connector DT-T DT-T DT-T DT-T (Gray) DT-T (Black) PACKARD PACKARD HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 DT DT (Black) DT (Black) DT (Black) DT DT DT (Black) DT (Black) DT DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T DT-T DT DT-T DT-T DT (Gray) M Terminal One-pin connector One-pin connector One-pin connector M M M M M M PACKARD M M M M Number of pin 1 2 2 2 40 40 12 8 1 1 1 1 6 2 2 2 1 1 2 6 2 2 2 2 2 2 1 1 1 1 1 1 2 1 1 6 2 2 1 1 1 1 1 1 4 4 3 8 8 3 2 9 31 31 31 31 14 31 31 31 6 8 8 8 6 6 8 8 6 8 8 8 8 8 8 8 6 6 6 2 2 12 3 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 Grounding Diode Diode Diode Engine controller Engine controller Intermediate connector Intermediate connector Grounding Grounding Grounding Grounding Front brake cutting switch Radiator coolant level sensor Washer motor Air conditioner dual switch Flasher Flasher Fuel temperature sensor Fog lamp switch (If equipped) Air cleaner clogging sensor Spare terminal Spare terminal Spare terminal Spare terminal Spare terminal Fuel shut-off valve Fuel shut-off valve + Fuse box (30 A) Fuse box (120 A x 2) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Grounding Engine block GND Steering flow switch Heater unit Heater unit Hazard switch Heater control Hoist EPC valve Grounding Horn switch Horn valve Horn valve Horn valve Horn valve Intermediate connector Hoist lever potentiometer Hoist selector valve Intermediate connector Intermediate connector Intake air pressure sensor Intake air temperature sensor Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Data link crossover Intermediate connector Lever kick-out solenoid Intermediate connector Rheostat Emergency steering motor Rear view monitor (If equipped) Rear view monitor (If equipped) Rear view monitor (If equipped) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Engine oil pressure sensor Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector N7 N7 O7 U9 U9 U9 U9 U9 V3 AE5 M8, N9 M8, N9 M8, O9 M8, O9 Location Address AH9 AJ8 AJ8 AE5 AG5 AG9 V9 AJ7 C9, C8, E9, G9 P1 X7 O2 N3 B3 B3 B2 R1 R1 AF9 N1 B7 X6 X7 X7 X7 X6 AE7 AE7 C9 C9 S1 AF8 K3 M4 M4 O7 AJ7 L5 Q8 A4 A4 A4 A3 V3 V3 L5 L6 L6 AF8 AF8 I2 I2 I2 H1, AN6 H1, AN6 H1 G1 G1 G1 AI6 AI5 AH5 AG5 AG5 AH5 AI5 AI6 AI6 X5 X5 X5 X4 X4 S9 V3 AD7 AD7 AJ6 U3 V3 I2 M1 Connector No. OP5 OP6 OP7 OPS PL01 PL02 PL03 PL04 PL05 PL06 PL07 PM1 PM3 PM4 PM5 PM6 PM7 PM7 PM8 PM9 PM10 PM11 PMLA PMPR PMRA POW PR01 PR02 PR03 PR04 PR05 PR06 PR07 PSOL PSW PUMP PWL PWM PWR R R R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R14 R15 R16 R17 R19 R21 R22 R25 R29 R30 R32 R33 R34 R35 R37 R40 R43 R44 R45 RAD RAIL RDC RE1 RE2 RE3 RE4 RESW RETV RL RL2 RP RPR RT2 RT6 RT7 RT8 RTL S01 S02 S03 S04 S05 SBS SDE SF1 SF2 SIG SLG Type of connector M M M DT-T M M One-pin connector One-pin connector One-pin connector One-pin connector Terminal MIC DT-T S (Natural color) MIC AMP040 AMP AMP BENDIX MIC S (Natural color) MIC DT-T (Gray) PACKARD DT-T HD30 M M One-pin connector One-pin connector One-pin connector One-pin connector Terminal DT-T DT-T PACKARD One-pin connector M One-pin connector One-pin connector One-pin connector Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay YAZAKI Relay Relay Relay Relay YAZAKI YAZAKI Relay Relay Relay Relay Relay YAZAKI PACKARD YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI DT-T DT-T YAZAKI One-pin connector DT-T PACKARD Terminal Terminal Terminal Terminal DT-T DT-T DT-T DT-T DT-T DT-T DT-T M DT-T (Green) DT-T HD30 Terminal Number of pin 1 1 1 2 2 2 1 1 1 1 1 21 3 16 13 12 9 9 5 21 16 21 12 3 6 21 2 2 1 1 1 1 1 2 2 3 1 6 1 1 1 5 5 5 5 6 6 5 5 5 5 5 5 5 6 5 5 6 5 11 5 5 5 6 7 7 5 6 5 5 5 9 3 9 2 2 2 2 2 2 2 1 6 3 1 1 1 1 6 2 2 2 2 2 2 6 12 2 31 1 Location Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Seat heater Left head lamp (LOW) Left head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (If equipped) Grounding VHMS wiring harness Pitch angle sensor VHMS wiring harnes Payload meter controller Payload meter controller VHMS wiring harnes Payload meter controller Connector VHMS wiring harness VHMS wiring harnes Intermediate connector Intermediate connector Fuel pump pressure sensor Intermediate connector Intermediate connector Right head lamp (LOW) Right head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (Optional) Grounding Parking brake solenoid Parking brake switch Fuel pump actuator Power window motor (Left) Power mode switch Power window motor (Right) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Engine starting relay Transmission Neutral relay Parking brake relay Brake lamp relay (RL) Backup lamp, buzzer relay Fog lamp relay AISS relay Brake lamp relay (CTR) Brake lamp timer relay PLM GDL relay Horn relay Brake cutting relay Transmission cutting relay Hazard relay 1 Hazard relay 2 Parking brake safety relay Side lamp relay Rotary lamp relay Power window relay Head lamp Hi relay Head lamp Lo relay Dust indicator relay Parking brake manual switch Power window switch (Left) Power window switch (Right) Auto preheater relay Payload meter relay (If equipped) Green outside pilot lamp relay of payload meter Yellow outside pilot lamp relay of payload meter Red outside pilot lamp relay of payload meter AM/FM radio Fuel rail actuator Cassette stereo Resistor Resistor Resistor Resistor Retarder switch Retarder valve Room lamp Room lamp 2 Intermediate connector Fuel rail pressure sensor Emergency steering timer Emergency steering timer Emergency steering timer Emergency steering timer Retarder potentiometer Service brake switch Secondary brake switch Front brake cutting solenoid (If equipped) Auto suspension solenoid 1 (If equipped) Auto suspension solenoid 2 (If equipped) Seat belt switch Side lamp switch (If equipped) Shift lever Shift lever Intermediate connector Grounding AB4 AB3 AB3 AB3 AB2 AC4 AB4 AB3 AB2 AC4 AC4 AB4 A2 AB1 AC1 AC4 AC4 AD3 AC1 AD2 AD1 AC1 R9 S1 S9 AD3 AD2 AD2 AD2 AD1 O2 AF5 O2 S9 S9 P8 P8 L4 L4 E9 G9 A6 AI6 M4 M5 M5 M4 P8 B7 E9 E9 F9 F9 U2 N2 R9 Q9 AJ7 C8 N7 N7 T9 T9 V9 H9 AF5 D8 AJ7 A5 A4 A5 A5 A5 A6 A4 L6 K3 AF5 I2 M4 C7 Address M8, O9 N8, O8 N8, O8 T2 D1 D2 E1 E1 E1 D1 D2 T9 X7 T9 T9 U9 Connector No. SLG SLL SLR S-NET SP1 SP2 SPA1 SPA2 SPA3 SPL SPR SR2 SR3 SUFL SUFR SURL SURR T01 T02 T05 T1 TEST TG TG2 TIMG TM2 TM3 TMF TPR TR VHM WFM WFR WPS WSRL WSRR CAN1 DLSW EG4 GDL GR1 GR2 HM-12 HM-21A HM-21B HM-22A HM-22B HM-23A HM-23B HM-31 HM-35 HM50 HM55 HM81 HM-2130 HM-2140 HM-CN1 HM-CN2A HM-CN2B HM-CN3A HM-CN3B HM-CN4A HM-CN4B LM1 LM2 ORB-A ORB-B PDL PLM PM1 PM4 PM11 SPA1 SPA2 VDL VHM VHMS WAKE Type of connector Terminal M M MS3102A 14S PACKARD PACKARD DT-T DT-T DT-T YAZAKI YAZAKI X X DT-T DT-T DT-T DT-T DT-T DT-T Terminal Terminal One-pin connector One-pin connector One-pin connector PACKARD HD30 HD30 DT-T PACKARD DT-T (Black) M Relay DT-T (Black) DT-T DT-T DT-T Terminal DT-T DT-T Terminal Terminal DT-T DT DT DT DT DT-T DT-T DT DT DT-T DT-T M YAZAKI YAZAKI AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 Terminal Terminal AMP070 AMP070 MS MS MIC S MIC DT-T DT-T MS DT-T MS Terminal Number of pin 1 1 1 5 2 2 4 12 6 2 2 3 2 3 3 3 3 2 6 1 1 1 1 1 3 21 31 2 3 6 8 6 6 12 2 2 3 1 12 12 1 1 3 2 2 2 2 3 3 2 2 3 3 8 2 2 20 18 12 18 12 14 10 1 1 14 10 5 5 21 16 21 4 12 5 8 5 1 Grounding Side lamp (If equipped) Side lamp (If equipped) S-NET monitor Engine speed sensor (Master) Engine speed sensor (Backup) Spare connector 1 Spare connector 2 Spare connector 3 Speaker (Left) Speaker (Right) Steering speed sensor Pitch angle sensor Suspension oil pressure sensor(FL) (If equipped) Suspension oil pressure sensor(FR) (If equipped) Suspension oil pressure sensor(RL) (If equipped) Suspension oil pressure sensor(RR) (If equipped) Fuel level gauge sensor Retarder oil temperature sensor Grounding Grounding TEST switch Tachograph Tachograph Timing rail actuator Intermediate connector Intermediate connector Transmission oil filter sensor Timing rail pressure sensor Brake lamp timer Intermediate connector Front wiper motor Front wiper relay Wiper switch Wheel speed sensor (RL) Wheel speed sensor (RR) VHMS intermediate connector Ground level download box VHMS intermediate connector Ground level download box intermediate connector Ground level download box Ground level download box Blow-by sensor Exhaust temperature sensor Exhaust temperature sensor Exhaust temperature sensor - amp intermediate connector Exhaust temperature sensor - amp intermediate connector VHMS - exhaust temperature amp intermediate connector VHMS - exhaust temperature amp intermediate connector Engine oil temperature sensor Ambient temperature sensor Short connector Short connector VHMS - Orbcomm controller intermediate connector Resistor Resistor VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller Ground level download box lamp terminal Ground level download box lamp terminal Orbcomm controller Orbcomm controller Ground level download box PLM connector PLM II download connector PLM II intermediate connector PLM II intermediate connector VHMS intermediate connector Ambient temperature sensor intermediate connector Ground level download box intermediate connector Ground level download box VHMS connector Blow-by, oil temperature sensor intermediate connector VHMS download connector Ground level download box F1 G9 F9 P1 X7 H1 B7 L8 J9 G9 H9 I9 AC9 V8 S9 S9 AG9 AD8 AD8 J3 AI6 X7 C2 Q1 R1 Q8 K1 K1 AU2 AO1 AV3 AP4 AP2 AP2 AM6 AN8 AN7 AR8 AQ7 AR8 AQ7 AN1 AM1 AU2 AQ6 AT2 AQ2 AR2 AS8 AT7 AU7 AT8 AS8 AU7 AT8 AP3 AP3 AS2 AS2 AP2 AQ6 AV3 AU7 AV6 AO6 AO6 AP3 AM6 AT2 AP2 Location Address J2 J2 C7 T1 AJ8 AJ8 Connector No. ABS ABS1 ABS1 ABS2 ABS2 ABS3 ABS3A ABS3B ABS4 ABS4 ABS5 ABS5A ABS6 ABS7 ABS8 ABSFL ABSFR ABSRL ABSRR BPFL BPFR BPRL BPRR BRC3B BRC4 BRC5A CHK CVF CVR CVSF CVSR DA1 DPC2B FOGF FOGM J06 JABS RABS RABS2 S01F S01M S02F S02M WSFL WSFR WSRL2 WSRR2 Type of connector M MIC DT-T MIC DT-T DT-T 40 40 40 DT-T DT 40 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T 40 40 40 Yazaki DT-T DT-T DT-T DT-T DT-T AMP070 M M HD30 DT-T KES1 KES1 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T Number of pin 6 17 6 21 8 6 20 16 12 6 6 20 6 6 6 2 2 2 2 3 3 3 3 16 12 20 6 2 2 3 3 2 12 6 6 31 12 6 6 3 3 3 3 2 2 2 2 ABS system switch ABS controller Joint connector ABS controller Joint connector Joint connector ABS controller ABS controller ABS controller Joint connector Joint connector ABS controller Joint connector Joint connector Joint connector ABS valve ABS valve ABS valve ABS valve Brake oil pressure Brake oil pressure Brake oil pressure Brake oil pressure Retarder controller Retarder controller Retarder controller System check switch ABS cut solenoid ABS cut solenoid ABS cut switch ABS cut switch Diode Machine monitor Fog lamp switch Fog lamp switch Intermediate connector Intermediate connector ABS cut relay ABS cut valve relay Service brake switch Service brake switch Secondary brake switch Secondary brake switch Wheel speed sensor Wheel speed sensor Wheel speed sensor Wheel speed sensor
CONNECTORS TABLE (A1 SIZE)
HD465, 605-7
Location
Address BK7 BR3 BF9 BR3 BD2 BE2 BR8 BQ9 BR8 BE2 BF3 BR8 BG8 BH8 BE9 AX9 AX9 BH7 BF9 AW9 AX9 BH8 BG9 BO9 BP9 BQ9 BL8 AZ8 BG9 AY8 BH8 BE9 P1 BM1 BK8 BD1 BA9 BS7 BS7 BC1 AZ1 BC9 BC9 BC1 AY7 BG9 BF9
VHMS controller related
HD465-7, HD605-7
90-27
(12)
ARRANGEMENT DRAWING (A1 SIZE)
ARRANGEMENT DRAWING (A1 SIZE)
HD465, 605-7
HD465-7, HD605-7
90-29
(12)

HD465 7 Shop Manual SN 7001 Up

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HD465 7 Shop Manual SN 7001 Up

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SEBM027612

MACHINE MODEL HD465-7 HD605-7

SERIAL NUMBER 7001 and up 7001 and up

2006 All Rights Reserved Printed in Japan 02-06(02)

Indication Page to be newly added Page to be replaced Page to be deleted

Action required Add Replace Discard

Pages having no marks are those previously revised or made aditions.

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HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

Loctite 648-50 LG-1

LG-6 Gasket sealant LG-7

Three bond 1211 Three bond 1207B

Komatsu code LM-G

Part No. 09940-00051

Molybdenum disulphide lubricant

400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can

Used for heavy load portion

Glass container Glass container Glass container

Can Adhesive for cab glass

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5

STANDARD TIGHTENING TORQUE

Width across flat mm 14 17 22 Nm 59 74 98 123 235 285

Tightening torque kgm 6 7.5 10 12.5 23.5 29.5

Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42

Width across flat mm

Varies depending on type of connector.

Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52