HD465-7R Smanu

SEN02283-00
DUMP TRUCK
HD465 -7R
HD605 -7R
HD465-15001
SERIAL NUMBERS and up
HD605-16001
SEN02285-00
DUMP TRUCK 1SHOP MANUAL
HD465-7R
HD605-7R
Machine model Serial number

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

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

Table of contents ............................................................................................................................................. 3
HD465-7R, HD605-7R 1
SEN02285-00 00 Index and foreword
Composition of shop manual 1

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

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

Engine and cooling system SEN02291-00
Power train system, Part 1 SEN02292-00
Steering system SEN02294-00
Brake system SEN02295-00
Undercarriage and frame SEN02296-00
Hydraulic system SEN02297-00
Cab and its attachments SEN02298-00
Electrical system, Part 1 SEN02299-00
90 Diagrams and drawings SEN02312-00

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

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

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

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

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

Form No. SEN02285-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (02)
6 HD465-7R, HD605-7R
SEN02286-00
DUMP TRUCK 1SHOP MANUAL
HD465-7R
HD605-7R

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

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

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HD465-7R, HD605-7R 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 HD465-7R, HD605-7R
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

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

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

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

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HD465-7R, HD605-7R 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HD465-7R, HD605-7R
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HD465-7R, HD605-7R 19
Connectors newly used for Tier 3 engines

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 HD465-7R, HD605-7R
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

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

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

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

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 HD465-7R, HD605-7R
2. Table of tightening torques for split flange bolts

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

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

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
HD465-7R, HD605-7R 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

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

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
HD465-7R, HD605-7R 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 HD465-7R, HD605-7R
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
HD465-7R, HD605-7R 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 HD465-7R, HD605-7R
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HD465-7R, HD605-7R 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 HD465-7R, HD605-7R

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

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

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

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

Gross
(rear) kg 66,760 (68%)
3
Struck m 25
Dump body capacity
Heaped (2 :1) m3 34.2
Performance
Max. travel speed km/h 70
Gradeability (sin ) % 37
Min. turning radius m 8.5
Dumping angle ° 48
Overall length mm 9,355
Overall width mm 4,595
Overall height mm 4,400

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

Tread
Rear wheel mm 3,080
Ground clearance mm 604
Model KOMATSU SAA6D170E-5
Type 4-cycle, water-cooled, in-line 6-cylinder,

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

Max. torque Nm/rpm{kgm/rpm} 3,324/1,400 {339/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 196 {146}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 2 units
HD465-7R, HD605-7R 3
Structure 3-element, 1-stage, 2-phase

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

Type Fully automatic, electrically-hydraulically
Transmission actuated, force-feed type pump
Power train
No. of speeds F7, R1
Type Spiral bevel gear, splash lubrication

Reduction gear Reduction ratio 3.538
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

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

Axle type
Suspension
Rear axle Full floating
Front axle Hydropneumatic

(Automatic damping force selection type)
Suspension method
Rear axle Hydropneumatic
Front tire 24.00 – 35 – 36PR x 2

Size and No.
Tires
Rear tire 24.00 – 35 – 36PR x 4

Tire pressure Front and rear tire kPa {kg/cm2} 470 {4.75}
Front wheel Single dry disc type, Hydraulically controlled

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

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

For both steering and work equipment

Type Gear pump
Delivery /min 348

(at engine rated speed 2,000 rpm)
Hydraulic pump
For charging torque converter

Type Gear pump
Delivery /min 228

Hydraulic system
For brake cooling
Type Gear pump

Delivery /min 456
Hoist cylinder
Type 2-stage piston type

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

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

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

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

Gross
(rear) kg 74,310 (68%)
Struck m3 29
Dump body capacity
Heaped (2 :1) m3 40
Performance
Max. travel speed km/h 70
Gradeability (sin ) % 37
Min. turning radius m 8.5
Dumping angle ° 48
Overall length mm 9,355
Overall width mm 4,595
Overall height mm 4,400

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

Tread
Rear wheel mm 3,080
Ground clearance mm 604
Model KOMATSU SAA6D170E-5
Type 4-cycle, water-cooled, in-line 6-cylinder,

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

Max. torque Nm/rpm{kgm/rpm} 3,324/1,400 {339/1,400}
Fuel consumption (Min.) g/kWh {g/HPh} 196 {146}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 2 units
6 HD465-7R, HD605-7R
Structure 3-element, 1-stage, 2-phase

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

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

Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

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

Axle type
Suspension
Rear axle Full floating
Front axle Hydropneumatic

(Automatic damping force selection type)
Suspension method
Rear axle Hydropneumatic
Front tire 24.00 R35 aa x 2

Size and No.
Tires
Rear tire 24.00 R35 aa x 4

Tire pressure Front and rear tire kPa {kg/cm }
2 686 {7.0}
Front wheel Single dry disc type, Hydraulically controlled

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

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

For both steering and work equipment

Type Gear pump
Delivery /min 348

Hydraulic pump
For charging torque converter

Type Gear pump
Delivery /min 228

Hydraulic system
For brake cooling
Type Gear pump

Delivery /min 456
Hoist cylinder
Type 2-stage piston type

(only 2nd stage: double-acting)
Cylinder
No. – bore (1st – 2nd) x stroke 2 – (170 mm – 150 mm) x 1,774 mm
Steering cylinder
Type Piston type, double acting
No. – bore x stroke 2 – 85 mm x 410 mm
8 HD465-7R, HD605-7R
Weight table 1
This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model HD465-7R HD605-7R
Serial Number 15001 and up 16001 and up
Engine assembly 3,030 3,030

Output shaft assembly 123 123
Radiator assembly 405 405
Fuel tank 294 294
Torque converter assembly 412 412
Transmission assembly 1,264 1,264
Drive shaft assembly (front) 26 26
Drive shaft assembly (rear) 62 62
Rear axle assembly 6,293 6,293
• Differential 774 774
• Final drive (one-side) 1,421 1,421
• Rear brake (one-side) 721 721
Front axle (one-side) 330 330
Front brake (one-side) 142 142
Front suspension cylinder 460 460
Rear suspension cylinder 176 176
Frame 4,680 4,680
Cab (Platform) 1,104 1,104
Operator's seat 63 63
Steering cylinder 44 44
Hoist cylinder 206 206
Demand valve 26 26
Steering valve 20 20
Hoist valve 34 34
Hydraulic pump (SDR(30)–100+100) 40 40
Hydraulic pump (SDR(30)–80+80(1)6) 38 38
Hydraulic pump (SDR(30)100+(1)25) 26 26
Dump body 10,730 13,418
HD465-7R, HD605-7R 9
Fuel, coolant and lubricants 1
10 HD465-7R, HD605-7R
Engine Oil Transmission Steering, Front Rear Differential

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

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

Fuel tank
case system
Specified oil 32 each for

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

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

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

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

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

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

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

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

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

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

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

2. Fuel pre-filter (with water separator)
3. Over flow
4. Nozzle spill
5. Feed pump
6. Fuel tank
7. Water separator
4 HD465-7R, HD605-7R
Brake oil cooler 1
1. Cooler element Oil cooler specifications

Element type : Multiple plate
A: Oil inlet Radiation surface : 8.13 m2
B: Oil outlet Pressure resistance (oil side): 2.9 MPa {30 kg/cm2}
C: Coolant inlet
D: Coolant outlet
HD465-7R, HD605-7R 5
Output shaft 1
1. Rubber cushion Function

2. Outer body The output shaft is installed to the engine flywheel,
3. Flange and absorbs the twisting vibration caused by
4. Shaft changes in the engine torque.
5. Coupling
6. Inner body
7. Cover
6 HD465-7R, HD605-7R
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between flywheel size Shaft Hole clearance limit
1
and bearing
–0.015 –0.010 –0.045 –
100 0.02
–0.015 –0.045 0.005
Clearance between shaft and –0.010 –0.015 –0.005 – Replace
2 55 0.10
bearing –0.040 –0.015 0.040
Clearance between bearing +0.006 –0.008 –0.039 –
3 150 0.06
and cover –0.024 –0.033 0.016
Clearance between bearing +0.025 +0.005 –0.050 –
4 85 0.013
and shaft +0.003 –0.025 0.002
Standard size Repair limit
Wear of oil seal contact sur- Repair or
5 –0.1
face of coupling 110 replace
–0.1
Standard backlash Backlash limit
6 Backlash at spline
0.080 – 0.231 0.4
Standard backlash
Original dimension: Lo
(Dimension at smallest width: L) Replace
Defomation of rubber cushion
7 90 81
75 67
External No cracks
HD465-7R, HD605-7R 7

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

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

Power train system, Part 1
Power train skeleton ....................................................................................................................................... 2
Drive shaft....................................................................................................................................................... 4
Torque converter and transmission hydraulic piping....................................................................................... 6
Brake cooling oil control valve (BCV).............................................................................................................. 8
Torque converter ........................................................................................................................................... 10
Torque converter valve.................................................................................................................................. 17
Transmission................................................................................................................................................. 19
Transmission control valve............................................................................................................................ 35
ECMV............................................................................................................................................................ 36
HD465-7R, HD605-7R 1
Power train skeleton 1
2 HD465-7R, HD605-7R
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling pump
(SDR(30)100+100)
5. Torque converter transmission charge pump
and brake cooling brake control pump
(SDR(30)100+SA(1)25)
6. PTO
7. Torque converter
8. Transmission
9. Rear drive shaft
10. Differential gear
11. Drive shaft
12. Brake
13. Tire
14. Final drive
15. Parking brake
16. Steering, hoist and hoist control pump
(SDR(30)80+80+SB(1)6)
HD465-7R, HD605-7R 3
Drive shaft 1
1. Front drive shaft Outline

2. Rear drive shaft q The power from the engine is transmitted
through the output shaft, the front drive shaft
(1) and the transmission, to the rear drive shaft
(2).
4 HD465-7R, HD605-7R
Torque converter and transmission hydraulic piping 1
6 HD465-7R, HD605-7R
1. Torque converter
2. Transmission
3. Oil filler tube
4. Hydraulic pump (SDR(30)100+25)
5. Torque converter valve
6. Transmission oil filter
7. Brake cooling oil control valve (BCV)
HD465-7R, HD605-7R 7
Brake cooling oil control valve (BCV) 1
1. Pilot relief valve assembly Function

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

direct travel
At gear shift (in direct travel)

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

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

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

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

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

Power train system, Part 2
Axle ................................................................................................................................................................. 2
Differential ....................................................................................................................................................... 4
Final drive ....................................................................................................................................................... 5
Wheels ............................................................................................................................................................ 6
HD465-7R, HD605-7R 1
Axle 1
Front
1. Wheel hub
Unit: mm
Repair or
2 Wear of oil seal sliding surface –0.130
280 — replace
–0.130
2 HD465-7R, HD605-7R
Rear
1. Differential Specifications
2. Axle housing Reduction ratio
3. Brake Differential: 3.538
4. Final drive Final drive : 4.737
Oil
Differential: T030-CD (95 liters)
Final drive : T030-CD (32 liters each side)
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
Rim size: 17.00-35
HD465-7R, HD605-7R 3
Differential 1
1. Coupling Specifications
2. Cross shaft Type: Spiral bevel gear, splash-type lubrication
3. Bevel gear (No. of teeth: 46) Reduction ratio: 3.538
4. Side gear (No. of teeth: 24) Differential: Straight bevel gear, splash-type
5. Pinion gear (No. of teeth: 17) lubrication
6. Bevel pinion (No. of teeth: 13) Oil: T030-CD (95 liters)
Unit: mm
Wear of oil seal contact sur- Repair or
7 –0.100
face of coupling 150 — replace
–0.100
Thickness of side gear thrust –0.100
8 6 5.5 Replace
washer –0.050
Backlash between bevel gear
9 0.41 – 0.56 Adjust
and pinion
4 HD465-7R, HD605-7R
Final drive 1
1. Sun gear (No. of teeth: 19) Specification

2. Planet gear (No. of teeth: 24) Type: Planetary gear, splash-type lubrication
3. Planet gear shaft Reduction ratio: 4.737
4. Ring gear (No. of teeth: 71) Oil: T030-CD (32 liters each side)
5. Inner hub
6. Wheel hub
7. Drive shaft
Unit: mm
Backlash between planet gear Standard backlash Repair limit
8
and sun gear 0.22 – 0.67 0.8
Replace
Backlash between planet gear
9 0.28 – 0.77 1.0
and ring gear
Repair or
10 Curvature of drive shaft Repair limit: 1.5 TIR
replace
11 Thickness of spacer Replace
51.5 ±0.1 50
HD465-7R, HD605-7R 5
Wheels 1
Front wheel
1. Tire
2. Rim assembly
3. Valve
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
Rear wheel
1. Rim assembly
2. Valve
3. Extension
Specifications
Rim size: 17.00 x 35
Tire size : 24.00-35 (HD465-7R)
24.00R35 (HD605-7R)
6 HD465-7R, HD605-7R

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

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

Steering system
Steering column .............................................................................................................................................. 2
Steering linkage .............................................................................................................................................. 3
HD465-7R, HD605-7R 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
2 HD465-7R, HD605-7R
Steering linkage 1
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm
HD465-7R, HD605-7R 3
4 HD465-7R, HD605-7R
Unit: mm
Clearance between inner and size Shaft Hole clearance limit
5
outer for knuckle arm bushing
0.150 –
165 0.7
0.300
Clearance between bushing –0.035 +0.054 0–
6 85 0.3
and pin –0.035 +0.054 0.089
Clearance between steering
–0.025 +0.069 0.055 –
7 cylinder mounting pin and 45 0.3
–0.064 +0.030 0.133
bushing
Clearance between inner and 0.120 –
8 80 0.4
outer bushing 0.250
Clearance between tie rod –0.025 +0.069 0.055 –
9 40 0.3
mounting pin and bushing –0.064 +0.030 0.133
10 110 0.4
outer bushing 0.250
Replace
Clearance between arm –0.030 +0.076 0.060 –
11 55 0.3
12 100 0.5
outer bushing 0.180
Clearance between arm –0.030 +0.091 0.075 –
13 70 0.3
Clearance between center
–0.030 +0.197 0.167 –
14 lever mounting pin and bush- 55 1.0
–0.076 +0.137 0.273
ing
15 80 0.4
outer bushing 0.250
Clearance between tie rod –0.025 +0.069 0.055 –
16 40 0.3
Clearance between suspen-
–0.030 +0.046 0.030 –
17 sion cylinder mounting pin and 60 0.3
–0.076 +0.054 0.122
bushing
HD465-7R, HD605-7R 5

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

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

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

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

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

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

Upper portion
• When oil fills the rear brake cylinders and the
pr e s s ur e b et we en p or t ( A ) an d po r t ( C )
becomes high, the oil entering port (H) from ori-
fice (e) of spool (3) pushes against spring (4). It
pushes up spool (3) and shuts off the circuit
between port (A) and port (C). When this hap-
pens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
HD465-7R, HD605-7R 5
Lower portion Brake released

• When spool (3) in the upper portion moves up Upper portion
and the circuit between port (A) and port (C) is • When pedal (1) is released and the operating
shut off, oil also fills the front brake cylinder at force is removed from the top of the spool, the
the same time, so the pressure in the circuit back pressure from the brake cylinder and the
between port (B) and port (D) rises. The oil force of the spool return spring move spool (3)
entering port (J) from orifice (f) of spool (5) up. Drain port (a) is opened and the oil from the
pushes up spool (5) by the same amount that brake cylinder flows to the brake system tank
spool (3) moves, and shuts off port (B) and port return circuit to release the rear brakes.
(D). Drain port (b) is closed, so the oil entering
the brake cylinder is held, and the brake is Lower portion
applied. • When the pedal is released, spool (3) in the
• The pressure in the space in the upper portion upper portion moves up. At the same time, the
is balanced with the operating force of the back pressure from the brake cylinder and the
pedal, and the pressure in the space in the force of the spool return spring move spool (5)
lower portion is balanced with the pressure in up. Drain port (b) is opened and the oil from the
the space in the upper portion. When spools (3) brake cylinder flows to the brake system tank
and (5) move to the end of their stroke, the cir- return circuit to release the front brake.
cuits between ports (A) and (C) and between
ports (B) and (D) are fully opened, so the pres-
sure in the space in the upper and lower por-
tions and the pressure in the left and right brake
cylinders is the same as the pressure from the
pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
6 HD465-7R, HD605-7R
Secondary brake valve 1
1. Rod Function
2. Spool q This valve operates the brake depending on
3. Cylinder the parking brake release pressure controlled
by the secondary brake pedal.
A: To parking brake valve
P: From accumulator
T: To brake system tank
HD465-7R, HD605-7R 7
Relay valve 1
1. Spool Function
2. Upper cylinder q This valve operates the front brake depending
3. Lower cylinder on the parking brake release pressure con-
4. Spool trolled by the secondary brake pedal.
A: To front brake
P: From accumulator
Pp: From secondary brake valve
8 HD465-7R, HD605-7R
Front brake off valve 1
1. Connector Function
2. Solenoid q This valve is installed on the brake oil circuit
between the brake valve and the front brake.
A: To front brake When the front brake off switch of the opera-
P: From brake valve tor's seat is pressed, the solenoid is energized,
T: To brake system tank and the valve cuts off the circuit between the
brake valve and the front brake.
HD465-7R, HD605-7R 9
Accumulator charge valve 1
ACC:To accumulator Specification

P: From hydraulic pump q Cut in pressure: 14.2 MPa {145 kg/cm2}
PP: From accumulator q Cut out pressure: 20.6 MPa {210 kg/cm2}
H1: Relief valve Function
R1: Relief valve
q The accumulator charge valve is actuated to
R3: Main relief valve
maintain the oil pressure from the pump at the
specified pressure and to store it in the accu-
mulator.
q When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
10 HD465-7R, HD605-7R
1. Main relief valve (R3) 4. Relief valve (H1)

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

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

q When the pressure at port (B) (accumula- q If the pressure at port (P) (pump pressure)
tor pressure) reaches the set pressure of goes above the set pressure of the relief valve
the relief valve (R1), poppet (6) separates (R3), the oil from the pump pushes spring (3).
from valve seat (7), so an oil flow is gener- Ball (11) is pushed up and the oil flows to the
ated and the circuit is relieved. brake oil tank circuit, so this set the maximum
q When the circuit is relieved, a pressure pressure in the brake circuit and protects the
difference is generated above and below circuit.
piston (8), so piston (8) moves up, poppet
(6) is forcibly opened, and port (C) and
port (T) are short circuited.
q The spring chamber at the right end of
spool (15) is connected to port (C) of the
relief valve (R1), so the pressure becomes
the brake oil tank pressure.
q The pressure at port (P) drops in the same
way to a pressure equivalent to the load
on spring (14), so the supply of oil to port
(B) is stopped.
HD465-7R, HD605-7R 13
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibil-
ity of the gas to absorb the pulse of the hydrau-
lic pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Front brake
Gas used : Nitrogen gas
Charge amount : 3,500 cc
Charging pressure: 11.8 MPa {120 kg/cm2}
Rear brake, Parking brake

Gas used : Nitrogen gas
Charge amount : 4,000 cc
Charging pressure: 6.9 MPa {70 kg/cm2}
14 HD465-7R, HD605-7R
Slack adjuster 1
1. Cylinder Specifications
2. Check valve Piston operation pressure:
3. Piston 9.8 – 19.6 kPa {0.1 – 0.2 kg/cm2}
Check valve cracking pressure
A: Inlet port (When cooling pressure is 0):
B: Outlet port 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2}
Check valve closing pressure:
1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}
Unit: mm
Clearance between body and size Shaft Hole clearance limit
4
piston
–0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Standard size Repair limit Replace
Spring Installed Installed Installed
Free length
5 Slack adjuster spring coefficient length load load
0.45 N/mm 45.6 N
97 — —
{0.046 kg/mm} {4.7 kg}
HD465-7R, HD605-7R 15
Function q If the brake pedal is depressed further, and the

q The slack adjuster is installed in the brake oil oil pressure discharged from the brake valve
line from the brake valve to the brake piston. It goes above to set pressure, check valve (3)
acts to keep the clearance between the brake opens and the pressure is applied to port (C) to
piston and discs constant even when the brake act as the braking force.
discs are worn. in this way it acts to keep a Therefore, when the brake is applied, the time
constant time lag when the brake is operated. lag is a fixed value.
Operation
1. When brake pedal is depressed
q Before the brake is depressed, piston (4) is
returned by the distance of stoke (S) (full
stroke). When the brake pedal is depressed,
the oil discharged from the brake valve flows
from port (P) of the slack adjuster and is
divided to left and right cylinders (2), where it
moves piston (4) by stroke (S) to the left and
right.
2. When brake pedal is released

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

distance of stroke (S). In this condition, the
closer the clearance between the brake piston
and dics is to 0, the greater the braking force
becomes.
16 HD465-7R, HD605-7R
Brake 1
Front
1. Piston
2. Pad
3. Disc
Unit: mm
Wear of pad (remaining thick- Standard size Repair limit
4
ness of wear material) 19.5 3.0 Replace
5 Missing portion of pad — Ratio of surface: 10%
Correct or
6 Face runout of disc (Note 1) 0.15 0.50
replace
Wear of disc
7 30 Less than 27
(thickness of disc) Replace
Open crack in radial direction
8 Damage to disc surface — Electric wear, marked damage
Correct
(Note 2)
Note 1: • If there is excessive face runout of the disc, check the front wheel bearing also.
Note 2: • If the depth of the scratch exceeds 1.5 mm.
• If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate
metal is melted to the disc, or there is protrusion.
• If there are vertical scratches other than concentric scratches.
HD465-7R, HD605-7R 17
Rear
1. Inner gear
2. Retainer
3. Outer gear
4. Plate
5. Disc
6. Damper
7. Piston
8. Spring (for parking brake)
9. Cylinder
10. Piston (for parking brake)
18 HD465-7R, HD605-7R
Unit: mm
Backlash between outer gear Standard size Repair limit
11
and plate 0.21 – 0.64 2.2
Backlash between inner gear
12 0.21 – 0.64 2.2
and disc
13 Thickness of plate
2.4 2.15
14 Thickness of disc 5.1 4.6
15 Thickness of damper 6.9 5.1 Replace
16 Thickness of damper 3.4 3.0
Distortion of disc friction Standard distortion Repair limit
17
surface Max. 0.45 0.7
Distortion of plate and damper
18 Max. 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
19
and disc 97.9 90.9
HD465-7R, HD605-7R 19
Function Operation of parking brake

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

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

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

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

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

q The suspension system supports the weight of damper) by contracting and expanding the
the chassis, and absorbs the shock from nitrogen gas and oil to absorb the load from
uneven road surfaces to provide a comfortable the road surface.
ride for the operator. At the same time, it main- q In addition to these functions, the front suspen-
tains the stability of the machine by ensuring sion employs an automatic suspension sys-
that all four wheels are always in contact with tem. In this system, the force of the suspension
the ground surface. In this way, it allows the is automatically changed by selecting the
machine to demonstrate its full performance in dumping force to match the travel conditions
items such as acceleration, braking, and turn- and load conditions. This further increases the
ing, even when traveling at high speed. stability and riding comfort of the machine.
q Hydropneumatic cylinders are used for the
suspension cylinders to reduce the shock. With
hydropneumatic cylinders, the suspension cyl-
inder is charged (sealed) with oil and nitrogen
2 HD465-7R, HD605-7R
Function
1. Front suspension
The front suspension cylinder functions as a
shock absorber and spring, and is connected
by spherical bearings to the lower arm (A-
frame) and main frame. The wheels move up
and down in accordance with the retraction
and extension of the suspension cylinder to
maintain the proper alignment for the wheels
and to improve the stability of the machine.
2. Rear suspension
The differential housing is supported by the
frame and two radius rods at the bottom, and at
the top by two inverted-V-shaped rods and two
suspension cylinders. It is connected to these at
both ends by spherical bearings. It transmits the
load and motive force through the top and bot-
tom rods.
The inverted-V-shaped rods at the top also
function to maintain the center of the machine
(axle).
Employment of the inverted-V-shaped link im-
proves the rolling steering characteristics.
HD465-7R, HD605-7R 3
Suspension cylinder 1
Front
1. Feed valve 7. Hydraulic cylinder

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

Clearance between piston rod size Shaft Hole clearance limit Replace
11
and bushing bushing
–0.043 +0.240 0.103 –
160 0.4
–0.106 +0.006 0.346
Clearance between piston rod –0.043 +0.540 0.403 – Replace
12 160 0.7
and bushing –0.106 +0.360 0.646 bushing
Clearance between cylinder –0.05 +0.115 0.05 – Replace
13 200 0.8
and wear ring –0.26 +0.115 0.375 wear ring
Repair limit
14 Elasticity of leaf spring

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

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

In the valve body, bypass circuit (D) is provided
before and after orifice plate (8a), so the oil
flow is divided into oil flowing through orifice
plate (8a) and oil flowing through the bypass
circuit (D).
The oil flowing through bypass circuit (D)
passes through a shaft with orifices at two
places on the inside circumference, and flows
to oil chamber (C) or oil chamber (B) according
to whether it is retracting or extending.
The shaft is connected to an air cylinder driven
by a signal from the retarder controller, and the
size of the orifices automatically changes
according to the condition of the machine.
The damping force is set at three levels (ME-
DIUM, HARD, SOFT) according to the size of
the orifices through which the oil is passing.
HD465-7R, HD605-7R 7
Rear
1. Feed valve
2. Cylinder
3. Rod
4. Valve (for bleeding air and mounting pressure sensor)
5. Ball
8 HD465-7R, HD605-7R
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
6
and bushing
–0.043 +0.306 0.103 –
180 0.5
–0.106 +0.060 0.412
Replace
Clearance between piston rod –0.043 +0.246 0.043 –
7 180 0.4
and bushing –0.106 +0.246 0.352
Clearance between cylinder –0.050 +0.115 0.05 –
8 220 0.8
and wear ring –0.260 –0.008 0.375
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(6) through orifices (4) and (5) to cavity (2), the oil is
throttled by the orifices and a shock-absorbing
effect is obtained.
a) Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (7) is compressed, the oil in chamber
(6) is sent through both orifices (4) and (5) to
cavity (2), and cavity (2) is filled more quickly
than when extending.
b) Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and
axle and the pressure of the nitrogen inside
chamber (7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil
remaining in cavity (2). 1. Valve (for bleeding 7. Nitrogen gas chamber
This pressurized oil closes orifice (4) with and mounting pres- 8. Cylinder rod
check ball (3), and is sent to chamber (6) sure sensor) 9. Cylinder
through only orifice (5), so the flow of oil pass- 2. Cavity 10. Feed valve
ing through the orifice is controlled so that it is 3. Check ball
less than during retraction. 4. Orifice a: When extending
In this way, the amount of oil returning to 5. Orifice b: When retracting
chamber (6) is restricted to provide a shock 6. Oil chamber
absorbing effect.
HD465-7R, HD605-7R 9
Rear axle support 1
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
10 HD465-7R, HD605-7R
Unit: mm
Clearance between rod mount- size Shaft Hole clearance limit
5
ing pin and bushing
–0.030 +0.046 0.030 –
70 1.0
–0.076 +0.046 0.122
6 100 0.5 Replace
outer bushing 0.180
Clearance between suspen-
–0.030 +0.046 0.030 –
7 sion cylinder mounting pin and 70 0.3
–0.076 +0.046 0.122
frame or axle
8 100 0.5
outer bushing 0.180
HD465-7R, HD605-7R 11

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

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

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

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

2. Hydraulic pump (SDR(30)80+80+(1)6) q The positioner sensor senses the body opera-
3. Hoist valve tion, and from this data the retarder controller
4. EPC valve controls output to the EPC valve.
5. Body positioner sensor q The signal from the dump lever is controlled by
6. Hoist cylinder the retarder controller, and actuates the EPC
valve. The pilot pressure generated by the
EPC valve moves the spool of the hoist valve
and controls the hoist cylinder.
4 HD465-7R, HD605-7R
Hydraulic tank 1
1. Breather
2. Drain
3. Oil level gauge
Capacity: 97 l
HD465-7R, HD605-7R 5
Steering valve 1
1. Input shaft 8. Ball a: From steering control valve

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

steering control valve and enters port (P) of the
steering valve
q Valve spool (3) is at the neutral position, so
port (P) and the port (RT and LT) to cylinder
are closed. No oil flows to the cylinder, so the
cylinder does not move.
q At the same times, port (LS) is connected
trough port (R) to the tank. As a result, there is
no oil pressure at port (LS), so all the oil from
the pump at the steering control valve flows to
the hoist valve.
HD465-7R, HD605-7R 7
2. Steering to right
(When steering wheel is turned to the right)
q When the steering wheel is turned (to the q The oil returning from the steering cylinder
right), input shaft (1) rotates. When this hap- flows from port (LT) trough port (E) and port (R)
pens, valve spool (3) moves down. (Input shaft and goes back to the tank.
(1) has a spiral groove in which ball (8) moves, q At the same time, the oil pressure at port (P) is
so when input shaft (1) rotates, torsion bar (9) restricted by valve spool (3), and passes
is twisted, and all (8) moves up or down to trough port (A), so a lower oil pressure (the
move valve spool (3).) drop in pressure (pressure difference) differs to
q The oil from the steering control valve flows according to the area of the opening of the
from port (P) through port (A) and port (G) and spool) than the pressure at port (P) is applied
goes to port (F). to port (LS).
q The oil at port (F) then passes between stator q The steering control valve spool is actuated by
(6) and rotor (12) in the metering position. After the difference in pressure between the oil pres-
the amount of oil flowing to steering cylinder is sure at port (P) end and the oil pressure at the
measured here, it enters the inside of valve port (LS) end. As a result, only the necessary
spool (3), passes through hole (a) in the valve amount of oil flows to the steering circuit, and
spool through port (RT) and flows to the steer- remaining oil flows from the steering control
ing cylinder. valve to the hoist valve.
q In this way, the two cylinders are actuated and
the wheels turn to the right.
8 HD465-7R, HD605-7R
3. Steering to left
(When the steering wheel is turned to the left.)
q When steering wheel is turned (to the left), q At the same time, the oil pressure at port (P) is
input shaft (1) rotates. When this happens, restricted by valve spool (3), so a lower oil
valve spool (3) moves up. pressure than the pressure at port (P) is
q The oil from the steering control valve flows applied to port (LS).
from port (P) enters port (B) passes trough q The steering control valve spool is actuated by
hole (a) in valve spool (3), and enters the the difference in pressure between the oil pres-
inside of the valve spool. sure at port (P) end and the oil pressure at the
q The oil inside valve spool (3) passes between port (LS) end. As a result, only the necessary
stator (6) and rotor (12) in metering portion. amount of oil flows to steering circuit, and
After the amount of oil flowing to the steering remaining oil flows from the steering control
cylinder is measured here, it flows to port (F). valve to the hoist circuit.
q The oil at port (F) passes trough port (LT) and
flows to steering cylinder.
q In this way, the two cylinders are actuated and
the wheels turn to the left.
q The oil returning from the steering cylinder
flows from port (RT) trough port (D) and port
(R) and goes back to the tank.
HD465-7R, HD605-7R 9
Crossover relief valve 1
SC1: To steering cylinder 1. Valve body

SC2: To steering cylinder 2. Valve seat
SC3: To steering cylinder 3. Relief valve
SC4: To steering cylinder 4. Valve spring
SV1: To steering valve 5. Sleeve
SV2: To steering valve 6. Adjustment screw
7. Lock nut
10 HD465-7R, HD605-7R
Steering cylinder 1
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit Replace
1
and bushing bushing
–0.030 +0.163 0.036 –
55 0.567
–0.104 +0.006 0.267
Clearance between piston rod +0.039
2 45 — — 1.0
supports shaft and bushing +0.039
Clearance between cylinder Replace
+0.039
3 bottom support shaft and bush- 45 — — 1.0
+0.039
ing
HD465-7R, HD605-7R 11
Steering control valve 1
12 HD465-7R, HD605-7R
P1: From hydraulic pump

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

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

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

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

The area of opening of the steering control
valve orifice is small, so the difference in
pressure between the two sides of the ori-
fice is large. As a result, the movement to
the right increases, and all some of oil
from the steering pump flows to the steer-
ing valve. The remaining oil from the
steering pump and all the oil from the hoist
pump flows to the hoist valve.
16 HD465-7R, HD605-7R
Steering relief valve q When the pressures in port (A) and port (B)
balance with the poppet spring force (set pres-
sure), the pilot poppet (3) will open. Oil in port
(B) will escape through port (D) to port (C), and
the pressure in port (B) will lower.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw q When the pressure in port (B) lowers, the ori-
fice of the main valve (1) generates a differen-
Function tial pressure between ports (A) and (B), and
the pressure in port (A) pushes to opens the
q This valve is located in the steering control
main valve (1) to release oil from port (A).
valve and release oil from the pump to prevent
the pump from being damaged when the steer-
ing cylinder comes to the stroke end, or when
an abnormal pressure occurs. (This valve sets
the maximum pressure of the circuit.)
Operation
q Port (A) is connected to the pump circuit, and
port (C) is connected to the tank drain circuit.
q Oil flows through the orifice of the main valve
(1), and port (B) is filled with oil.
q Also, the pilot poppet (3) is seated to the valve
seat (2).
HD465-7R, HD605-7R 17
Hoist valve 1
18 HD465-7R, HD605-7R
T: To tank
P: From flow amplifier
A1: To hoist cylinder bottom
B1: To hoist cylinder head
PA: From EPC valve (pressurized side in lowering or floating operation)
PB: From EPC valve (pressurized side in lifting operation)
1. Body
2. Spool
3. Retainer
4. Spring (lifting)
5. Relief valve
6. Spring (floating)
7. Spring (lowering)
8. Retainer
9. Retainer
10. Retainer
11. Check valve
Unit: mm
Free length Installed Installed Installed
Free length
12 Relief valve poppet spring x O.D. length load load
259 N 233 N
49.3 x 12.8 41.9 —
{26.4 kg} {23.8 kg}
If damaged or
44 N 40 N
13 Check valve spring 32.6 x 10.9 24.5 — deformated,
{4.5 kg} {4.1 kg}
replace the
156 N 140 N spring
14 Spool return spring (lifting) 51.3 x 34.5 50 —
{15.9 kg} {14.3 kg}
124 N 112 N
15 Spool return spring (lowering) 34.2 x 28.7 32 —
{12.7 kg} {11.4 kg}
927 N 849 N
16 Spool return spring (floating) 74.0 x 36.0 55.5 —
{94.5 kg} {85.1 kg}
HD465-7R, HD605-7R 19
Operation
1. Hoist valve HOLD position
q Oil from the steering control valve flows into q Since both the bottom side port and the head
chamber (C). Since the hoist spool (2) blocks side port of the hoist cylinder are blocked, the
the path to the hoist cylinder, oil flows through hoist cylinder is locked where it is.
chamber (D) to the tank.
20 HD465-7R, HD605-7R
2. Hoist valve at LIFT position
q When the hoist lever in the cab is set to the q Oil flows out of chamber (A), flows in the bot-
RAISE position, pressurized oil from the sole- tom side of the hoist cylinder, extends the hoist
noid valve pushes the hoist spool (2) to the left. cylinder and raise the body.
q Therefore, oil from chamber (C) opens the q On the other hand, the return oil from the head
check valve (11) and flows into chamber (A). side flows out of chamber (B), flows into cham-
ber (D) and to the tank circuit.
HD465-7R, HD605-7R 21
3. Hoist valve at FLOAT position
q When the hoist lever in the cab is set to the q Since the bottom side and the head side of the
FLOAT position, pressurized oil from the sole- hoist cylinder are connected through the hoist
noid valve pushes the hoist spool (2) to the valve, the hoist cylinder is in a free state.
right. Then, chambers (C), (D), (B), (H) and
(D) are all connected.
q Oil from the steering control valve flows from
chamber (C) through chamber (B) to the host
cylinder and from chamber (C) through cham-
ber (D) to the oil cooler circuit.
22 HD465-7R, HD605-7R
4. Hoist valve at LOWER position
q When the hoist lever in the cab is set from the q On the other hand, the return oil from the head
FLOAT position to the LOWER position, pres- side of the hoist cylinder flows out of chamber
surized oil from the solenoid valve pushes the (A) and flows into chamber (H).
hoist spool (2) to the right further from the q At the time of lowering, the output pressure of
FLOAT position. Therefore, oil from chamber the solenoid valve rises over the cracking pres-
(C) pushes to open the check valve (11) and sure of the pilot check valve, and therefore, the
flows into chamber (B). return oil from chamber (H) returns through
q Then, oil flows into the head side of the hoist chamber (D) to the tank.
cylinder through chamber (B), retracts the hoist
cylinder and lowers the body.
HD465-7R, HD605-7R 23
EPC valve 1
1. Manual operation button Function

2. Solenoid assembly q The EPC valve controlled by the retarder con-
3. Solenoid assembly troller switches the pilot pressure of the hoist
valve, and controls pressure, and controls the
A: To hoist valve hoist valve.
B: From hoist valve
T1: To hydraulic tank
T2: To hydraulic tank
24 HD465-7R, HD605-7R
Hoist cylinder 1
Unit: mm
Clearance between cylinder and size Shaft Hole clearance limit
1
bushing
–0.043 +0.264 0.089 –
170 0.707
–0.143 +0.046 0.407
Clearance between piston rod –0.036 +0.207 0.103 – Replace
2 100 0.693
and bushing –0.123 +0.067 0.393
Clearance between piston rod +0.004
3 70 — — 1.0
support pin and bushing –0.019
Clearance between cylinder sup- +0.004
4 70 — — 1.0
port pin and bushing –0.019
HD465-7R, HD605-7R 25
Hydraulic pump 1
Steering, hoist and hoist control pump
SDR(30)80+80+SB(1)6
Unit: mm
Model Standard clearance Clearance limit
SDR(30)-80
1 Side clearance 0.16 – 0.20 0.24
SDR(30)-80
SBR(1)-6 0.10 – 0.15 0.19
Clearance between inside SDR(30)-80
diameter of plain bearing and 0.06 – 0.131 0.20
2 SDR(30)-80 Replace
outside of diameter of gear
shaft SBR(1)-6 0.06 – 0.119 0.20
Model Standard size Tolerance Repair limit
SDR(30)-80 –0.5
3 Depth to knock in pin 10
SDR(30)-80 –0.5 —
SBR(1)-6 9.1 ± 0.3
4 Rotating torque of spline shaft 15.8 – 28.5 Nm {1.6 – 2.9 kgm}
Standard
Rotating Delivery Delivery
delivery
Model speed pressure amount limit
amount
Discharge amount (rpm) MPa {kg/cm2} ( /min)
( /min) —
— Oil: EO10-CD
Oil temperature: 45–55°C SDR(30)-80
184.5 170.4
SDR(30)-80 2,500 20.6 {210}
SBR(1)-6 13.8 12.6
26 HD465-7R, HD605-7R
Retarder cooling pump

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

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

SBL(1)-014
Unit: mm
1 Clearance between gear case
and side plate, gear SBL(1)-014 0.10 – 0.15 0.19
Clearance between inside
2 diameter of plain bearing and SBL(1)-014 0.06 – 0.119 0.20
outside diameter of gear shaft Replace
3 Depth to knock in pin –0.5
SBL(1)-014 10 —
–0.5
4 Rotating torque of splined shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Standard Delivery
Rotating
Delivery delivery amount
Delivery amount Model speed
pressure amount limit
— Oil: EO10-CD (rpm) —
( /min.) ( /min.)
Temperature: 45 – 55°C
20.6 MPa
SBL(1)-014 3,500 45.7 42.4
{210 kg/cm2}
HD465-7R, HD605-7R 29

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

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

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

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

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

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

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

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

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

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

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

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

2. Engine tachometer 27. Turn signal pilot lamp (right)
3. Retarder oil temperature gauge 28. Turn signal pilot lamp (left)
4. Torque converter oil temperature gauge 29. Head lamp high beam pilot lamp
5. Coolant temperature gauge 30. Shift lever position pilot lamp
6. Fuel gauge 31. Shift indicator
7. Character display 32. Retarder pilot lamp
8. Centralized warning lamp 33. Lockup pilot lamp
9. Retarder oil temperature caution lamp 34. Output mode pilot lamp (power mode)
10. Torque converter oil temperature caution lamp 35. Output mode pilot lamp (economy mode)
11. Coolant temperature caution lamp 36. Suspension mode pilot lamp (hard)
12. Fuel level caution lamp (if equipped)
13. Maintenance caution lamp 37. Suspension mode pilot lamp (medium)
14. Battery charging circuit caution lamp (if equipped)
15. Steering oil temperature caution lamp 38. Suspension mode pilot lamp (soft) (if equipped)
16. Engine oil pressure caution lamp 39. ABS pilot lamp (if equipped)
17. Retarder oil pressure caution lamp 40. ASR pilot lamp (if equipped)
18. Parking brake caution lamp 41. Preheater pilot lamp
19. Machine monitor option system caution lamp 42 Automatic retarder READY pilot lamp
20. Engine system caution lamp (if equipped)
21. Transmission system caution lamp 43. Automatic retarder set speed indicator
22. Retarder system caution lamp (if equipped)
23. Inclination caution lamp 44. Automatic retarder set speed unit indicator (km/
24. Seat belt caution lamp h) (if equipped)
25. Body caution lamp 45. Automatic retarder set speed unit indicator
(MPH) (if equipped)
4 HD465-7R, HD605-7R
46. Rotary switch [SW1] a When setting, follow the instruction in Testing
47. Rotary switch [SW2] and adjusting, Adjusting machine monitor, and
48. Rotary switch [SW3] do not change them.
49. Dipswitch [SW5-4] a When moving the switches, use a precision
50. Dipswitch [SW5-3] screwdriver and turn slowly.
51. Dipswitch [SW5-2] a Be careful not to touch anything except the
52. SI Spec, Non-SI Spec selection switch [SW5-1] switches inside the grommet.
53. Dipswitch [SW6-4] a Be careful not to let any dirt or dust get in.
54. Dipswitch [SW6-3] a After completing the setting, return the grom-
55. Dipswitch [SW6-2] met securely to its original position.
56. Dipswitch [SW6-1]
HD465-7R, HD605-7R 5
Machine monitor normal display functions

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

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

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

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

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

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

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

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

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

when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
nance-related has been given
Mainte- alarm is given or Lit up or appear on the
13 nance LED Red the time to flashed — — character
caution change filter and display.
oil has elapsed. Note 2:For details on
the target items,
etc., see the
Operation &
Maintenance
Manual.
Battery
During battery
charging Lit up when
14 LED Red charging circuit
circuit abnormal.
being abnormal
caution
Steer-
When the
ing oil
steering oil Lit up when
15 tempera- Caution LED Red
temperature abnormal.
ture
rises.
caution
Engine
When the engine
oil pres- Lit up when
16 LED Red oil pressure
sure abnormal.
drops.
caution
Retarder When the
Operates when the
oil pres- retarder Lit up when
17 LED Red alternator R terminal is
sure oil pressure abnormal. (Note) (Note) ON.
caution drops.
Operates when the
Parking When the parking brake is oper-
Lit up during
18 brake LED Red parking brake is ated and the shift lever
operation. (Note) (Note)
caution operated. is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up when tions, used in the event
19 LED Red machine moni-
optional abnormal. of failure of the
tor or optional
system machine monitor.
controller system
caution
During being
Engine
abnormal in Lit up when
20 system LED Red
engine control abnormal.
caution
system.
8 HD465-7R, HD605-7R
Related When
ing buzzer ated.
lamp
Trans-
When transmis-
mission Lit up when
21
system
LED Red sion control sys-
abnormal.
tem is abnormal
caution
Retarder When retarder
Lit up when
22 system LED Red control system is
abnormal.
caution abnormal
When the body is
Inclina-
lifted and inclined Lit up when
23 tion LED Red
excessively abnormal.
caution
from side to side.
Caution
During
operation:
Seat- When the seat-
lit up
24 belt LED Red belt is not — —
During non-
caution fastened.
operation:
turned OFF.
During
See the operation: Note: Operates when
Body lit up the shift lever is in
25 LED Red instruction
caution manual During non- (Note) (Note) other than the "N"
operation: position.
turned OFF.
During
operation:
Emer- When the emer- lit up
26 gency LED Red gency steering is During non- — —
steering operated. operation:
turned OFF.
During
Turn operation:
lit up
27 signal, LED Green During operation During non- — —
right operation:
turned OFF.
During
Turn operation:
lit up
28 signal, LED Green During operation During non- — —
left operation:
turned OFF.
During
Head- operation:
light, lit up
29 LED Blue During operation During non- — —
high
beam Pilot operation:
turned OFF.
Shift
30 When the shift
lever
LED Green lever is in the "R" Lit up (*) — — * Blinks when the neu-
(R) position position tral safety is operated.
R
Shift
30 When the shift
lever
LED Orange lever is in the "N" Lit up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lit up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift
lever
LED Green lever is in the "6" Lit up (*) — — * Blinks when the neu-
(6) position position tral safety is operated.
6
Shift
30 When the shift
lever
5
HD465-7R, HD605-7R 9
Related opera- When

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

tion machine Immedi-
ing buzzer ated.
lamp
Suspen-
sion
Lit up in
mode In suspension
37 LED Green "medium" — —
(medium) "medium" mode
mode
(if
equipped)
Suspen-
sion
In suspension Lit up in "soft"
38 mode LED Green — —
"soft" mode mode
(soft) (if
equipped)
During
operation:
When ABS is
ABS (if lit up
39 LED Orange operated. — —
equipped) During non-
operation:
turned OFF
During
operation:
When ASR is
ASR (if lit up
40 LED Orange operated.
equipped) During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lit up
41 LED Red for preheating — —
ing During non-
engine is
operation:
Pilot operated.
turned OFF
Auto-
matic When auto- When ready
retarder matic retarder is to be
42 LED Green — —
being ready to be oper- operated:
ready (if ated. lit up
equipped)
Auto-
matic Back-
retarder ground When automatic Display of set * Zero is displayed
43 LCD retarder switch is — — when the set speed
set speed color:
turned ON. speed (*)
(if gray is cancelled.
equipped)
Auto-
matic During
When automatic
retarder operation:
retarder switch is
unit lit up
44 LED Green turned ON and — —
display During non-
the unit km/h is
(km/h) operation:
selected.
(if turned OFF
equipped)
auto-
During
matic When automatic
operation:
retarder retarder switch is
lit up
45 display LED Green turned on and — —
During non-
unit the unit MPH is
operation:
(MPH) (if selected.
turned OFF
equipped)
HD465-7R, HD605-7R 11
Self-diagnostic function when starting switch is

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

buzzer, monitor lamps, and meters
To check the normal display function of the
machine monitor, press the machine monitor check
switch to check the actuation. For details of the
actuation, see "Machine monitor normal display
functions when machine monitor check switch is
operated".
12 HD465-7R, HD605-7R
Service mode functions 2) ID input procedure

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

0.5 [V] at 0 [kPa]

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

200 – 950 [°C]

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

200 – 950 [°C]

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

2.0 [V] at 4.9 [Mpa]

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

2.0 [V] at 4.9 [Mpa]

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

q The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking
(for overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note:
1. Power mode gear speed (F4, F3, or F2) is maintained.
q For the shift-up point, the optimum point Accordingly, if the operator drives the machine
between 2,100 and 1,750 rpm is selected down a slope with the foot brake applied and
according to the amount of the accelerator the engine speed is kept low by the gear speed
pedal is depressed, the acceleration of the maintaining function, the cooling oil becomes
machine, and the speed range. insufficient and the engine tends to overheat.
q For the shift-down point also, the optimum q If the travel speed lowers below 1 km/h or the
point between 1,200 and 1,400 rpm is selected foot brake is not applied or the lock-up is kept
according to the amount the accelerator pedal turned on for a long period, the lock-up is
is depressed and the speed range. turned off and a gear speed proper for the
travel speed is selected.
2. Economy mode
q For the shift-up point, the optimum point 4. Lock-up
between 2,100 and 1,750 rpm is selected q The point to turn ON the torque converter
according to the amount the accelerator pedal lockup is set properly in the range from 1,250
is depressed, the acceleration of the machine, to 1,500 rpm according to the torque converter
and the speed range. inlet speed (engine speed) and outlet speed
q For the shift-down point also, the optimum (transmission input shaft speed) and accelera-
point between 1,200 and 1,400 rpm is selected tor pedal position.
according to the amount of the accelerator q The lockup-off point is 1,100 rpm.
pedal is depressed and the speed range. q If the operator starts driving the machine down
a slope with the accelerator pedal released,
3. Braking mode
the torque converter is not locked up until the
q While the foot brake is operated, if the travel
operator presses the accelerator pedal or
speed lowers below about 20 km/h at the 4th
applies the brake.
gear speed, about 15 km/h at 3rd gear speed,
or 11 km/h at the 2nd gear speed, the current
HD465-7R, HD605-7R 9
Gear shift lever positions and method of shifting 4) Gear shift lever position N
1) Gear shift lever position D At the neutral position, none of the transmis-
When shifting up (in power mode) sion clutches are actuated.
I) When the gear shift lever is set at position D,
the transmission is set to F2 torque converter Time when gear cannot be shifted
range. q In the automatic shift range, to prevent mis-
II) When the accelerator pedal is depressed, the taken operation caused by excessive variation
engine speed rises and accelerates. When the in the speed when shifting gear, a time delay is
transmission input shaft speed reaches 1,250 used to prevent the gears from being shifted
– 1,500 rpm, the lock-up clutch is engaged, so within the set time.
the torque converter is directly engaged and q The gearshifting time delay is controlled pre-
the transmission is set to direct travel. cisely by each gearshifting pattern through the
III) As the engine speed rises further and reaches use of the all-range electronic modulation sys-
1,750 – 2,100 rpm, the transmission shifts up tem.
to F3.
While the transmission is shifting up, the The approximate values for the gearshifting
engine speed is also lowered (a command is pattern and gearshifting time delay are shown
output to the engine controller) in order to in the diagram below.
reduce the shock when shifting gear.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine
accelerates, it rises again and the transmission
shifts up in turn to F4 to F7 in the same way as
in III) above.
When shifting down (in power mode)

I) When the load increases and the engine
speed drops to 1,200 – 1,550 rpm, the trans-
mission shifts down one speed.
(For example, when traveling in F7, the trans-
mission shifts down to F6.)
While the transmission is shifting up, the
engine speed is also raised (a command is
output to the engine controller) in order to
reduce the shock when shifting gear.
II) As the engine speed goes down further and
the transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque con-
verter drive.
a In the above explanation, the set speed or

actuation may differ according to the travel
conditions. For details, see the automatic
gearshifting graph.
2) Gear shift lever positions 6, 5, 4, 3, 2, L

The method of shifting automatically from F1 to
(F6, F5, F4, F3, F2) is the same as for "gear
shift lever position D" above.
3) Gear shift lever positions R
There is the gear shift lever position for travel-
ing in reverse.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
10 HD465-7R, HD605-7R
Safety functions 4) Power train overrun prevention rear brake

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

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

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

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

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

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

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

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

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

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

AABBCCDD

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

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

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

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

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

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

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

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

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])

*0******: Transmission oil filter clogging D_IN_1: Transmission oil filter switch 1
****1***: Cranking D_IN_3: Emergency escape switch
******0*: Non-operation emergency steering D_IN_4: C terminal signal
******1*: Operation emergency steering D_IN_6: Emergency steering relay
*******1: Shift lever N D_IN_7: Shift lever N
1*******: L fill D_IN_8: Fill signal L
*1******: 4th fill D_IN_9: Fill signal 4th
**1*****: H fill D_IN_10: Fill signal H
***1****: 1st fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
10010000: F1 time
00010010: R1 time
00000000: N time
11000000: F6 time
10000000: Shift lever R D_IN_16: Shift range R
01000000: Shift lever D D_IN_17: Shift range D
00100000: Shift lever 6 D_IN_18: Shift range 6
00000001: Shift lever L D_IN_23: Shift range L
*0******: Lowering of coolant level D_IN_25: Coolant level
**0*****: Clogging of air cleaner D_IN_26: Air cleaner switch
***0****: Operation of main pressure variable valve D_IN_27: Main pressure variable valve pressure switch
****0***: Operation of main oil flow selector valve D_IN_28: Main oil flow selector valve pressure switch
*****0**: Operation of lubricating oil flow variable valve D_IN_29: Lubricating oil flow variable valve pressure switch
* Plane does not use
HD465-7R, HD605-7R 19
Automatic emergency steering system 1
1. Timer Outline
2. Battery If the engine should stop when the machie is travel-
3. Emergency steering oil pressure switch ing, or there is any abnormality in the hydraulic
4. Emergency steering motor pump and the steering circuit oil pressure is
5. Emergency steering pump become below the specifed value, the emergency
6. Steering control valve system automatically actuates an electric pump to
ensure the hydraulic pressure for the steering,
thereby making it possible to use the steering.
This system can also be operated manually.
20 HD465-7R, HD605-7R
Relay timer
1. Dial Outline
2. Lock This relay timer is a delay timer to prevent emer-
3. Pin gency steering system from malfunctioning.
After the current flows in the coil for the time set by
Set time: 1 seconds the timer, the relay contacts are switched.
HD465-7R, HD605-7R 21
Automatic suspension system 1
1. Dump control lever Outline

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

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

ing when braking stronger when the brakes are
(Brake (Brake (Brake (Brake
applied. OFF) ON) OFF) ON)
Anti-lift To prevent the front The damping force is made
from lifting up when stronger when the dump body
dumping control lever is at any position (Float) (Other (Float) (Other
than than
except FLOAT. Float) Float)
High speed To improve stability Detects travel speed and
stability when traveling at selects damping force. (No con-
high speed trol when traveling empty)
HD465-7R, HD605-7R 23
Auto suspention solenoid valve
2. Solenoid q The automatic suspension solenoid valve is
installed in the circuit between the hydraulic
A: To hydraulic cylinder head pump and the suspension cylinder. The valve
B: To hydraulic cylinder bottom switches oil pressure of the hydraulic cylinder
P: From pump which is installed to the front suspension,
T: To transmission oil pan according to signal from the retarder controller.
Two solenoid valves are combined to select
three modes of Soft, Medium and Hard.
24 HD465-7R, HD605-7R
Retarder control system 1
HD465-7R, HD605-7R 25
Retarder controller
Outline according to the travel conditions and load

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

Retarder control system diagram
Retarder lever control

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

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

tional solenoid reducing valve, the output (trig-
ger output) is set to a high value.
B: To operate the hydraulic equipment smoothly
in the low pressure range, the output is set to a
high value.
C: In the range where the retarder is normally
used, the output is proportional to the angle of
the lever.
D: To release the hydraulic pressure smoothly in
the low pressure range, the output is set to a
low value.
HD465-7R, HD605-7R 29
Hoist control function

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

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

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

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

potentiometer or after replacing the retarder
controller, carry out calibration in the following
order.
Order of dump control calibration (hydraulic oil
temperature: 80 – 90°C)
1) While the body is seated completely, run
the engine and set the lever to HOLD and
then to FLOAT, and check that the float
caution lamp goes off.
2) Raise the body and keep the lever in the
RAISE position until the cylinder touches
the stopper. After the cylinder touches the
stopper, keep the lever in the RAISE posi-
tion for at least 5 seconds.
3) Lower the body to the seat, and then keep
the lever at the FLOAT position for at least
5 seconds.
HD465-7R, HD605-7R 31
Dump control lever
32 HD465-7R, HD605-7R
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HD465-7R, HD605-7R 33
Function
q When lever (1) is operated, rod (18) moves up
or down according to the amount the lever is
operated, and rotates potentiometer (16).
q The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this
is sent as a signal voltage to the controller.
q One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump lever operated to FLOAT
q When LOWER rod (2) is pushed by lever (1)
and moves down, ball (14) contacts protrusion
(a) of rod (11) during the stroke. (Before start
of actuation of mechanical detent)
q When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to
the outside, and rod (11) passes over protru-
sion (a).
q When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion
(b) of rod (19) by retainer (13) that is being
held by detent spring (20).
q Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and
protrusion (b) of rod (19), so the lever is held at
the FLOAT position.
34 HD465-7R, HD605-7R
2. Dump lever FLOAT canceled 4. Dump lever operated to RAISE

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

q When lever (1) is returned from the RAISE
position, it is pushed down by a force greater
than the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the N position.
HD465-7R, HD605-7R 35

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

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

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

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

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

equipped with the payload meter (having
VHMS) optionally, the payload meter (card
type) cannot be mounted.
q For setting procedure of payload meter (card
type) when it is installed for the first time,
replaced or removed, see "Testing and adjust-
ing".
HD465-7R, HD605-7R 3
Principle of calculation
1. Outline
A dump truck is supported by 4 suspension
cylinders. By measuring the total of the loads
on each cylinder, it is possible to know the load
mass on the springs of the dump truck.
The measurement of the load mass is obtained
by calculating the difference between the mass
when empty and the mass when full.
The load on each cylinder can be calculated
from the internal pressure and sectional area
of the suspension cylinder.
[Load bearing on suspension cylinder]
W = PB SB – PT (SB – ST)
Where
W = Load bearing on suspension cylinder
PB = Bottom pressure
PT = Top pressure
SB = Cross-sectional area of cylinder
ST = Cross-sectional area of rod
Because of the structure of the suspension cyl-

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

(Calibration) The travel speed and distance are detected
Drive the empty dump truck at a speed of from the travel signal sensor on the truck.
about 10 km/h for about 30 seconds, and then a Travel signal sensor:
measure the average load and use it as the Transmission output speed sensor
mass when empty.
The reason why the mass is measured while
the dump truck is traveling is that the sliding
resistance of the suspension cylinders must be
averaged by extracting and retracting the cylin-
ders by changing the condition of the dump
truck.
The measured mass when empty is saved as a
calibration data in the memory in the controller.
3. Measurement of mass when full

Load the dump truck and measure the mass at
that time. When loading for this purpose, set
the gear shift lever in the "N" position and set
the dump control lever in the "FLOAT" position
on a ground where the longitudinal inclination
of the dump truck is ± 5°.
4. Correction on slope
If the dump truck is loaded on a slope, the
measured mass is different from the mass
measured on a level ground. To solve this
problem, the longitudinal inclination of the
dump truck is measured and the measured
mass is corrected according to the inclination
angle. (Correction range of inclination angle: ±
5°)
HD465-7R, HD605-7R 5
Features of each device

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

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

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

(Counterclockwise) (Clockwise)
2. Speed compensation trimmer 0 – F rotary selector switch 0 : 107% –7 : 107% – F : 92%
3. Distance compensation trimmer 0 – F rotary selector switch 0 : 107% –7 : 107% – F : 92%
4. Model selector switch 0 – F rotary selector switch According to model selector code table
5. Memory card use switch 2-stage selector switch Up : Not used Down : Used
6. Clinometer use switch 2-stage selector switch Up : Not used Down : Used
7. Mass unit setting switch 2-stage selector switch Up: t (Metric ton), Down: US ton (Short ton)
Switch forcible prohibition setting Up : Permitted Down : Prohibited

8. switch 2-stage selector switch According to Permitted/prohibited setting
table for switches
Turn CLOCKWISE to DECREASE volume
B. Buzzer volume adjustment Rotatory volume Turn COUNTERCLOCKWISE to INCREASE
volume
a The switches are adjusted before the machine
is shipped. Only No. 7 and No. B can be
adjusted. For this reason, do not touch any
other switch.
HD465-7R, HD605-7R 7
q Table of model selector code
No. of model selector switches Model
2 HD465-7 STD Small-tire Komatsu engine
3 HD325-7 STD Large-tire Komatsu engine
A HD605-7 STD Large-tire Komatsu engine
q Permitted/prohibited setting table for switches
Left side switch No. 8
Top (permitted) Bottom (prohibited)
Top
Left (1) (2)
(memory card not used)
side
switch
No. 5 Bottom
(3) (4)
(memory card used)
(1) Left side switch No. 5 (top), No. 8 (top)

All switches can be operated.
(2) Left side switch No. 5 (top), No. 8 (bottom)
Calibration, data all clear, time, date set-
ting operations only are possible.
(3) Left side switch No. 5 (bottom), No. 8 (top)
All switches can be operated.
(4) Left side switch No. 5 (bottom), No. 8 (bot-
tom)
Calibration, data all clear, card dump,
time, date setting operations only are pos-
sible.
8 HD465-7R, HD605-7R
Payload meter has the following basic functions.

i) Power ON (reset)
When the power is turned ON, all functions are checked and displayed.
a If the engine is started during the flow for this display, even there are items left to display, the dis-
play will switch after several seconds to iii) Normal operation display.
HD465-7R, HD605-7R 9
Normal operation display
Shift lever Dump lever

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

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

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

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

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

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

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

The mass of the machine when empty is mea-
sured and this is used as the calibration data.
These data are retained even when the power
is turned OFF.
iii) Normal operation display (for details, see the
Operation and maintenance manual)
See the Normal operation display.
iv) External display lamp drive
(estimated display)
The chart on the right shows the mass display
level for the external display lamps during the
normal operation display.
The estimated display shows the estimation of
the total mass when one more load is added.
The applicable lamp flashes to prevent over-
load.
10 HD465-7R, HD605-7R
V) Content of memory (for details, see Operation

and maintenance manual)
a) Cycle data
a The period between one dumping opera-
tion and the next dumping operation is
taken as one cycle and the data are
recorded.
a The cycle data are recorded when the
dumping conditions are fulfilled (see right).
a The maximum limit for cycle data in mem-
ory is 2900 cycles.
Item Unit Range
Engine operation number Integer 1-65535

Month Month 1-12
Day Day 1-31
Time Hour Hour Displayed as 0-23 Displays value and set value at time of
Time Minute Minute 0-59 dumping
Machine ID Integer 0-200
Open ID Integer 0-200
Load mass t (Metric ton) or 0-6553.5
US ton (Short ton)
Empty travel time min 0-6553.5
Empty travel distance km 0-25.5
Empty max. travel speed km/h 0-99
Empty average travel speed km/h 0-99
Empty stopped time min 0-6553.5
Loading stopped time min 0-6553.5
Loaded travel time min 0-6553.5
Loaded travel distance km 0-25.5
Loaded max. travel speed km/h 0-99
Loaded average travel km/h 0-99
speed
Loaded stopped time min 0-6553.5
Dumping time min 0-25.5 Displays set value at time of dumping
Limit speed km/h 0-99
Warning items/cycle
Analog spare 1
MAX electric potential V 0-4.0
MIN electric potential V 0-4.0
Average electric potential V 0-4.0
Data processing on PC
Analog spare 2
Data inside cycle are handled
MAX electric potential V 0-4.0
separately as spare signal input data.
MIN electric potential V 0-4.0
Average electric potential V 0-4.0
Digital spare 1
Lo frequency Times 0-255
Digital spare 2
Lo frequency Times 0-255
HD465-7R, HD605-7R 11
b) Engine ON/OFF data

a Each time the engine was stopped and started is recorded.
a The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets.
Item Unit Range
Engine operation number Integer 1-65535 Consecutive number for operation of engine
Year (last 2 digits) Year 0-99

Month Month 1-12
Day Day 1-31 Shows when engine was switched ON
Time Hour Hour Displayed as 0-23
Time Minute Minute 0-59
Month Month 1-12
Day Day 1-31 Shows when engine was switched OFF
Aggregate load mass t (Metric ton) or 0-9999000 Total value between engine ON and engine
US ton (Short ton) OFF
Total number of cycles Times 0-9999
c) Abnormality, warning data

a Each time a payload meter abnormality or warning is generated or cancelled is recorded.
a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets
Item Unit Range
Engine operation number when According to 5

error code was generated Integer 0-65535
Frequency of generation Times 1-255
after engine is switched ON

Month Month 1-12
Shows when error code was generated
Day Day 1-31
Time Hour Hour (0 – 23) Displayed as 0-23
Engine operation number Integer 0-65535
when cancelled

Month Month 1-12
Shows when error code was cancelled
Day Day 1-31
Time Hour Hour (0 – 23) Displayed as 0-23
12 HD465-7R, HD605-7R
d) Data for aggregate load mass, total number of cycles

a It is possible to calculate and record again from any desired time the aggregate load mass and total
number of cycles for each time that the dumping conditions are fulfilled.
a The calculation is started again for both values when the data for aggregate load mass and total
number of cycles are cleared.
a The maximum limit in memory for aggregate load mass and total number of cycles is 999900.0 t
(Metric ton) or US ton (Short ton) and 9999 cycles respectively.
Item Unit Range
Aggregate load mass t (Metric ton) or 0-999900.0

Shows aggregate from time when data were
US ton (Short ton)
cleared
Total number of cycles Times 0-9999

Month Month 1-12
Day Day 1-31 Shows date and time when data were cleared
e) Other data
Content Item Unit Range
Operator check Machine ID Integer 0-200

mode set data Open ID Integer 0-200 Operator check mode set in input oper-
Limit speed km/h 0-99 ation
Option code Integer 0-11
Calibration Year (last 2 digits) Year 0-99
performance Month Month 1-12
Date and time when calibration was
data Day Day 1-31
performed
User write data Data 1 20 Characters Comments that can be written freely
Data 2 20 Characters into payload meter.
Data 3 20 Characters Note: Input and settings are possible
Data 4 20 Characters only from PC through cable communi-
cations.
(For details, see software manual.)
HD465-7R, HD605-7R 13
f) Calibration data
a These are saved in RAM each time calibration is performed.
a The maximum limit in memory for calibration data is 15 sets.
Item Unit Range
Year Year (last 2 digits) 00-99

Month Month 1-12
Day Day 1-31 Shows values and settings when cali-
Time Hour Hour 0-23 bration was performed
Model selection code Integer 0-F
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Shows values before compensation fac-
Mass on spring (front) t (Metric ton) 0-6553.5
tor was calculated
Mass on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
Front wheel tilt compensation factor Integer 0-9.99999
Rear wheel tilt compensation factor Integer 0-9.99999
Front wheel link factor Integer 0-9.99999
Rear wheel link factor Integer 0-9.99999
Mass on spring (empty) t (Metric ton) 0-6553.5
g) Load mass calculation data (analog data)

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

Month Month 1-12
Day Day 1-31
Time Hour Hour 0-23
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Mass on spring (front) t (Metric ton) 0-6553.5
Mass on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
Front wheel tilt compensation factor Integer 0-9.99999
Rear wheel tilt compensation factor Integer 0-9.99999
Front wheel link factor Integer 0-9.99999
Rear wheel link factor Integer 0-9.99999
Mass on spring (empty) t (Metric ton) 0-6553.5
(Calibration value)
Trimmer gain value Integer 0.7500 –1.2500
Load mass t (Metric ton) 0-6553.5
Backup battery voltage V 0-25.5
The above data items a) – g) are retained even when the power is switched OFF.
14 HD465-7R, HD605-7R
vi) Forced display of aggregate load mass, total x) Service check mode
number of cycles By operating the switches of payload meter ,
Forced display of existing abnormalities and it is possible to forcibly carry out display, set-
warnings ting, and correction of the following items.
By operating the TOTAL/SFT switch of payload
meter II, it is possible to carry out forcible dis- a) Detailed calibration data display
play of these items. The display shows the date, suspension
For details, see the Operation and Mainte- pressure, etc. when the latest calibration
nance Manual. was carried out.
vii) Operator check mode b) Detailed load mass calculation data dis-
By operating the switch of payload meter , it play (analog data)
is possible to carry out the following items. The display shows the suspension pres-
For details, see the Operation and Mainte- sure and machine angle used when calcu-
nance Manual. lating the present load mass.
a) Memory card dump
b) Data all clear c) Memory card dump (service area)
c) Abnormality, warning exists/cancelled, This writes all the data displayed for Items
input signal condition display 6-6 and 6-7 to the memory card inserted in
d) Machine ID setting the machine.
e) Open ID setting
f) Limit speed setting a This function is available only when the
g) Option code setting No. 5 switch on the left side of the control-
h) Time, date correction ler (memory card use switches) is set for
"Use"
viii) Dimming of display portion
It is possible to adjust the brightness of the d) Data all clear (service area)
payload meter display portion to 10 levels This forcibly deletes all the calibration data
with the LIGHT/INC switch. and analog data, except for the latest cali-
bration data.
ix) Downloading saved data
It is possible to download any data recorded in a Before clearing the data, always download
payload meter to a PC through a cable the data to a PC or carry out a) Card
(ANSI/E1A RS-232C). dump.
For details, see the PC software manual pro-
vided by Komatsu. e) Input signal condition display
This displays some of the signal condi-
tions for the sensors input to payload
meter and the present recognition con-
dition of the payload meter.
f) Forced initialization
This forcibly deletes all the data in payload
meter .
a Before carrying out this operation, check

the time and date. Always carry out the
operation with the machine unloaded. Do
not carry out the operation unless neces-
sary.
g) Extra load mass setting when loading

The extra load can be forcibly input or cor-
rected to set the load mass when loading.
Available range for setting: –9 – +9 (%)
HD465-7R, HD605-7R 15
h) Load mass fixed display and cycle data record-

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

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

setting
This is used to input and correct the values to
set the travel distance recognized as comple-
tion of loading by payload meter .
Possible set range: 0 – 255 (m)
j) Loading start recognition load mass setting
This is used to input and correct the values to
set the load mass recognized as the start of
loading by payload meter .
Possible set range:
HD325-7
1
480 – 1,480 [ x 100 t]
HD405-7
HD465-7E0
t
690 – 1,690 [ x 100
]
HD605-7E0
HD465-7R
t
690 – 1,690 [ x 100
]
HD605-7R
16 HD465-7R, HD605-7R
k) Zero ton display range setting

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

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

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

following functions can be downloaded to
a PC using the PC downloading software
provided by Komatsu.
q Calibration data
q Load mass calculation data (analog
data)
For details, see the software manual.
(1) Method of operation
ALways actuate the service check mode
Note, c) and d) are actuated on the
HD1200-1 when the parking brake is ON or
wh en th e br a k e l o c k i s O N, a n d o n
machines other than the HD1200-1 when
the shift lever is at the N position and
when the dump lever is at FLOAT.
f) is actuated only when the power is ON.
a When the service mode is working,
on the HD1200-1, set the parking
brake to ON or the brake lock to ON,
and on machines other than the
HD1200-1, set the shift lever to the N
position and the dump lever to
FLOAT. If they are operated to other
positions, the payload meter will
return to the normal operation display,
but in this case, the data set and input
in the service check mode may not be
processed correctly.
HD465-7R, HD605-7R 17
18 HD465-7R, HD605-7R
(a) Operation for calibration data display
1. Set to CHEC display, then press CAL/CLE

switch (1) for at least 2 seconds.
Display: CALO
2. Every time the CAL/CLE switch (1) is pressed, From CALO flashing Remarks
the display changes in the order shown on the Last 2 digits of year for date
1
right. when CAL was carried out
Month and day for date when
2 CAL was carried out
3. If MODE switch (2) is pressed at any time dur- Hour and minute for date
ing the display in Steps 1. or 2., the display will 3 when CAL was carried out
return to CHEC. (End) 4
Model selection switch (decimal
value) when CAL was carried out
5 x 98kPa P'FL (Front left) Suspension
pressure less than
6 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
7 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
8 x 98kPa P'RR (Rear right) XXX.X
t Mass on front axle Less than 100 t:

9
(= x/4DF2 (P'FL+P'RL)) XX.X
t Mass on rear axle More than 100 t:
10 XXX.X
(= x/4DR2 (P'RL+P'RR))
Appears when value is
Angle of tilt when CAL was negative
11 x O
180 rad carried out
(–) X.XX
12 Front axle tilt coefficient
13 Rear axle tilt coefficient

X.XXX
14 Front axle link coefficient
15 Rear axle link coefficient

Spring-up mass calculated Same number of digits as 9.
16 and 10.
according to calibration
17 CALO flashes
Returns to 1. and
repeats sequence
All displayed values are rounded to
the value given.
HD465-7R, HD605-7R 19
(b) Operation for payload calculation data (analog data) display
1. Set to CHEC display, then press LIGHT/INC

switch (1) for at least 2 seconds.
Display: ALLO (when data in memory is
less than 170 cycles)
A.FUL (when data in memory is
more than 170 cycles)
A.FUL (when data in memory is
more than 180 cycles)
2. Every time the LIGHT/INC switch (1) is pressed, From ALLO flashing or A.FUL
Remarks
the display changes in the order shown on the flashing
right. 1 Hour, minute

2 x 98kPa P'FL (Front left) Suspension
pressure less than
3. If MODE switch (2) is pressed at any time 3 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
during the display in Steps 1. or 2., the display 4 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
will return to CHEC. (End) 5 x 98kPa P'RR (Rear right)
t Mass on front axle Suspension
6 pressure less than
(= x/4DF2 (P'FL+P'RL))
100 x 98 kPa: XX.X
t Mass on rear axle More than 100 x 98 kPa:
7
(= x/4DR2 (P'RL+P'RR)) XXX.X
Appears when value is
Angle of tilt when CAL was negative
8 x 180 rad carried out O
(–) X.XX
9 Front axle tilt coefficient
10 Rear axle tilt coefficient X.XXX

11 Front axle link coefficient
12 Rear axle link coefficient
Spring-up mass calculated
13 t Same as 7. and 8.
according to calibration
14 — GT o Gain trimmer
15 t Present load mass Same as 7. and 8.
16 V Backup battery
X.X
Voltage
17 ALLO flashing
Returns to (1) and
repeats sequence
All displayed values are rounded to

the value given.
20 HD465-7R, HD605-7R
(c) Operation for memory card dump (service area) (d) Operation for data all clear (service area)
1. Set to CHEC display, then press TOTAL/SFT 1. Set to CHEC display, then press LIGHT/INC
switch (1) switch (1) and CAL/CLEswitch (2) at the same
Display: Cd : dP time for at least 2 seconds.
Display: A : CLE
2. Press TOTAL/SFT switch (1) again.
The main display will go out and memory card 2. Press CAL/CLE switch (2).
access lamp (3) will light up. The display will become A.CLE (lighted up),
When the memory card dump operation is and when the data all clear operation is com-
completed, it will return automatically to the pleted, it will return automatically to the CHEC
CHEC display. (End) display. (End)
If it is desired to stop the memory card dump If it is desired to stop the data all clear opera-
operation when the display is Cd : dP, press tion when the display is A : CLE, presss
MODE switch (2), and the display will return to MODE witch (3), and the display will return to
CHEC without performing the memory card CHEC without performing the data all clear
dump operation. operation.
The memory card dump function can be used a Before clearing the data, download the
only when the No. 5 switch (memory card use necessary data to a PC or carry out the
switch) on the left side of the controller is set to card dump operation in Item (c).
"Use".
HD465-7R, HD605-7R 21
(e) Operation for input signal condition display (2-d) Battery charge signal condition
Display: C4:XX (lights up for 3 seconds)
Engine running: C4 : oo
Engine stopped: C4 : — —
O
(2-e) Analog spare input 1 signal condition
X.X .... Input signal (V)
O
(2-f) Analog spare input 2 signal condition
X.X .... Same as C5
O
(2-g) Digital spare input 1 signal condition
1. Set to CHEC display, then press TOTAL/SFT
switch (1) and CAL/CLR switch (2) at the same
Hi:C7 : oo
time for at least 2 seconds.
Lo: C7 : — —
Display: S : CHE
O
(2-h) Digital spare input 2 signal condition
2. Every time CAL/CLR switch (1) is pressed, the
Display: C8 : XX (lights up for 3 seconds)
display changes in the order shown below.
X.X .... Same as C7
O
(2-a) Parking brake, brake lock switch signal condi-
(2-i) Travel speed display
tion [HD1200-1]
Display: C9 : XX
X.X .... Travel speed (km/h)
O
Either one ON:CL : oo
(2-j) Travel distance display
Both OFF:CL : — —
O
Travel distance with machine in present
(2-a’) Shift lever position signal condition
condition (empty or loaded) for that cycle
[except HD1200-1]
Display: C1: XX (lights up for 3 seconds)
XXXX .... (m)
"N":CL : oo
* If the value goes above 9999m, the display
Except "N":CL : — —
starts again from 0.
O
O
(2-b) Dump lever position signal condition
Go to next page
F. FLOAT:C2 : oo
Except FLOAT:C2 : — —
O
(2-c) Engine oil pressure signal condition
Engine running:C3 : oo
Engine stopped:C3 : — —
O
22 HD465-7R, HD605-7R
From previous page ( f ) Operation for performing forced initialization

O
(2-k) Payload meter present recognition display
Counter display
Empty stopped ............. 03.01

Empty traveling............. 01.02
Loading......................... 06.03
Loaded traveling........... 02.04
Loaded stopped............ 04.05
Dumping ....................... 05.06
1. Set to CHEC display, then press CAL/CLR
Invariable May change switche (11), TOTAL/SFT switch (2) and
according to
N signal when LIGHT/INC switch (3) at the same time for at
O dumping
least 2 seconds.
(2-l) Machine condition time display shown below Display: :
Every time CAL/CLR switch (1) is pressed,

the display advances one place in order from 2. Press CAL/CLR switch (1) for at least 2 sec-
a) to f). onds.
The display becomes : (lighted up)
a Empty traveling S1 : (2 seconds),
b Empty stopped S2 : and when all the data is completely cleared, it
c Loaded traveling S3 : automatically displays F.CAL. (End)
d Loaded stopped S4 : After that, it carries out the process from 10.3.
e Dumping S5 :
If it is desired to stop the forced initialization
f Loading S6 :
operation when the display is : ,
press MODE switch (4), and the display will
return to CHEC without performing the forced
initialization operation.
* The value for the
present machine
recognition con-
dition increases
in minutes in
real time.
3. If MODE switch (3) is pressed at any time dur-

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

completed, press MODE switch (4) at any time
to return to the CHEC display. (End)
24 HD465-7R, HD605-7R
( i ) Operation for setting loading completion recog- ( j ) Operation for setting loading start recognition
nition travel distance load mass
1. Set to PL: XX display, then press CAL/CLR 1. Set to O.SEL display, then press CAL/CLR
switch (4) switch (4)
Display: O.SEL Display: P.SEL
2. Press TOTAL/SFT switch (3). 2. Press TOTAL/SFT switch (2).

Display: XXX Display: XXXX
If it is necessary to correct the set- If it is necessary to correct the set-
ting for the units, press LIGHT/INC ting for the tens, press LIGHT/INC
switch (2) and correct. switch (2) and correct.
3. Press CAL/CLR switch (4). 3. Press CAL/CLR switch (4).

If it is necessary to correct the set- If it is necessary to correct the set-
ting for the tens, press LIGHT/INC ting for the hundreds, press LIGHT/
switch (2) and correct. INC switch (2) and correct.
4. Press CAL/CLR switch (4) again. 4. Press CAL/CLR switch (4) again.
If it is necessary to correct the setting If it is necessary to correct the set-
for the hundreds, press LIGHT/INC ting for the thousands, press LIGHT/
switch (2) and correct. INC switch (2) and correct.
5. If CAL/CLR switch (4) is pressed again, the 5. If CAL/CLR switch (4) is pressed again, the
display will return to XXX, so it is possible to display will return to Step 3, so it is possible to
correct the units again. correct again.
6. When the correction operation from Step 1. is 6. When the correction operation from Step 1. is
completed, pressMODE switch (1) at any time completed, press MODE switch (1) at any time
to return to the CHEC display after displaying to return to the CHEC display. (End)
O.XXX (input value). (End)
If it is impossible to set the input values even If it is impossible to set the input values even
when MODE switch (1) is pressed, it displays when MODE switch (1) is pressed, it returns to
O.XXX (input value) and returns to Step 2.. Step 1.
HD465-7R, HD605-7R 25
(k) Operation for setting 0 ton display range
1. Set to P.SEL display, then press CAL/CLR

switch (4)
Display: H.SEL
2. Press TOTAL/SFT switch (3).

Display: – – XX (present value)
If it is necessary to correct the set-
ting, press LIGHT/INC switch (2) and
correct.

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

If it is impossible to set the input values even

when MODE switch (1) is pressed, it displays
d.FAL (input value) and returns to Step 2.
1. Set to H.SEL display, then press CAL/CLR
switch (4)
Display: E.SEL
2. Press TOTAL/SFT switch (3).

Display: A.XXX
3. Press CAL/CLR switch (4).

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

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

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

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

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

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

(000-020) performed when there is
abnormality

abnormality
(000-022)
(000-023)
(000-024)
HD465-7R, HD605-7R 29
Order Error code display

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
11 Short circuit with Suspension pres- F-25 flashes All flash When Any time
power source in front sure sensor input removed
left suspension pres- signal is 220 x 98
sure sensor system kPa or more
power source in front
right suspension pres-
sure sensor system
power source in rear left
suspension pressure
sensor system
power source in rear
right suspension pres-
sure sensor system
15 Short circuit with Clinometer input F-31 flashes All flash When Any time
ground, disconnection signal above + 10 removed
in clinometer system
x 180 rad
16 Short circuit with power Clinometer input F-32 flashes
source in clinometer signal above – 10
system
x 180 rad
17 Calibration not per- Calibration data in F • CAL All flash When Any time
formed or abnormality in memory damaged flashes removed
RAM
18 Short circuit in external When coil is con- F-41 flashes See When Except when load-
display lamp No. 1 relay ducting electricity, Remarks removed ing (for external
relay coil short cir- column display lamps, see
19 Short circuit in external F-42 flashes
cuits with power Remarks column)
display lamp No. 2 relay
source
23 Defective cycle data See (*2) L.bad — Start of Start of dumping -
payload (*2) flashes empty travel start of empty
travel
24 Over speed limit Travel speed is SP:SP — Set value When problem
over set speed flashes – 2km/h occurs
limit
25 Defective communica- F-71 — When —
tions or defective setting F-73 removed
of option code F-80
F-81
F-91
F-92
F-93
F-94
F-95
F-96
F-97
F-98
F-99
30 HD465-7R, HD605-7R
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
abnormality
(000-026)
(000-027)
(000-028)
Records Applicable only when

(000-031) clinometer "use" switch
is at "use"
Calibration cannot be
abnormality
Records Load mass calculation

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

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

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

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

a For details of basic precautions, outlines, see
"Testing and adjusting".
VHMS controller
a For details of the basic precautions, outlines,
method of sending and receiving data, and the
procedure for the initial setup, see Testing and
adjusting.
Specifications
1. Voltage of power supply: DC20V - DC30V
2. Size (mm): W272 x D169 x H72
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine
controller. It also gives commands for transmitting
the accumulated data through the communications
satellite.
2 HD465-7R, HD605-7R
Communications (ORB• • • Orbcomm)

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

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

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

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

the payload meter and saves the data of each
transportation cycle. It displays, sets, and
operates various items through the machine
monitor and network.
When the payload meter is installed for the first
time or the VHMS controller is replaced, the
necessary items of the VHMS controller must
be set again.
Payload meter (card type) set for HD465/
605-5 can be installed for a user who needs a
memory card. If it is installed, however, have
the machine monitor and VHMS controller rec-
ognize that it will execute the functions of the
payload meter, by using rotary switch 2 of the
transmission controller and VHMS initial set-
ting tool.
For setting procedure, see Testing and adjust-
ing, "Initial setting of payload meter", and
"Replacing parts".
HD465-7R, HD605-7R 5
Electric circuit diagram

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

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

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

The distance and travel speed are obtained
from the signals of the travel signal sensor of
the dump truck and the travel speed correction
information.
a Travel signal sensor:
Transmission output shaft speed sensor
6 HD465-7R, HD605-7R
Initial setting of payload meter

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

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

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

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

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

This function is used to set a criterion of the
maximum travel speed for the machine control
system.
5. Setting of load mass to recognize start of

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

cator lamp
This function is used to change the indication
range of the outside indicator lamp. The condi-
tion for turning on the red lamp cannot be
changed. If it is changed, the red lamp cannot
warn of overloading.
8 HD465-7R, HD605-7R
Operating method
Select "PLM" in Service mode 1 on the machine monitor.
For method of selection, see Testing and adjusting, "Special functions of machine monitor (EMMS)".
HD465-7R, HD605-7R 9
1. Setting of travel distance to recognize com- 2. Correction of calculation of payload

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

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

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

For the method of displaying the fol-
lowing screen, see the steps up to the
above step.
q [
] switch:
Stop measurement and return
to the previous screen.
As measurement is executed, the q [>], [<] switches:
number of [ ] increases. When mea- Select "EMPTY WEIGHT" or
surement is finished, the next screen "LOADED WEIGHT".
appears automatically. q [ ] switch: Enter the selection.
3) Load the dump truck to measure the q [ ] switch:
weight of the fully loaded dump truck. Return to the previous screen.
If the weight of the empty dump truck
has been input and the dump truck
has been driven for about 3 minutes,
"LOADED WEIGHT" is displayed
when the menu is selected.
Check the unit of the input value. The
unit is indicated in the ( ) on the right
side of WEIGHT.
(METRIC): metric ton
(SHORT): short ton
ii) Check that measurement of the weight
of the fully loaded dump truck has
been completed.
q [ ] switch:
Return to the menu screen.
When loading is started, the menu screen
appears automatically. When indicating
the current load for reference while the
dump truck is being loaded, go out of
"Service mode 1" temporarily and return to
"Display of load/integrated odometer". On
this screen, you can check the current
load.
4) Measure the weight of the fully loaded
dump truck with the load meter and record
it (Write it on a sheet of paper, etc.)
5) Input the measured weight of the fully q [ ] switch:
loaded dump truck and drive the dump Check that measurement has
truck for about 3 minutes. been completed and go to the
next step.
q [ ] switch:
12 HD465-7R, HD605-7R
iii) Input the measured weight of the fully v) Move the dump truck to a place where
loaded dump truck. you can drive it for about 3 minutes.
[>] switch:
q q [] switch:
Number at cursor moves for- After getting ready for drive,
ward. press this switch and start
q [<] switch: driving the dump truck.
Number at cursor moves q [ ] switch:
backward. Return to the screen for input-
q [ ] switch: Enter number at cursor. ting values.
q [ ] switch: Drive the dump truck for about 3 min-
Return to the largest position utes (at a speed higher than 8 km/h)
of the number to input the to enter the relationship between the
value again. If this switch is weight of the dump truck and the sus-
pressed again, inputting of the pension pressure under that weight.
value is stopped and the previ- vi) Display the progress of measurement
ous screen appears. (Fig. 9).
a Inputtable range
HD465-7: A1 ± (A1 x 0.25) (metric ton)
However,
A1 ={43.6 [t] (Operating weight) + 46 [t]
(Load capacity)}
HD605-7:
A2 ± (A2 x 0.25) (metric ton)
However,
A2 ={46.8 [t] (Operating weight) + 63 [t]
(Load capacity)}
iv) Check the input value.
q [] switch:
Stop measurement and return
to the previous screen.
As measurement is executed, the
number of [ ] increases. When mea-
surement is finished, the next screen
appears automatically.
q [<] switch: Select "YES".

q [>] switch: Select "NO".
q [ ] switch: Enter.
HD465-7R, HD605-7R 13
6) Dump the load in the dump area. 3. Correction of level of inclination sensor
1) Move the dump truck to a level place.
2) Input the clinometer reading (F) at the cur-
rent position and that (R) after turning 180
degrees (stopping it in the opposite direc-
tion) on the same position and use the
average value as the standard level.
i) Enter value of (F).
q [ ] switch:
If the load is dumped with the dump lever,
the menu screen appears automatically.
If the load is dumped normally, correction
is finished.
q [ ] switch: Enter the flashing value.

q [ ] switch:
The current standard level value is
displayed on the upper line. The cli-
nometer value (F) at the current posi-
tion flashes. Enter it when it is
stabilized.
ii) Turn the dump truck 180 degrees
(Stop it in the opposite direction).
iii) Enter value of (R).
q [ ] switch: Enter the flashing value.

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

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

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

q [>] switch: Select "NO".
q [ ] switch: Enter.
HD465-7R, HD605-7R 17
Functions of communicating with external devices for purposes other than downloading
The following 2 functions of communicating with external devices are installed. They use the RS232C com-
munication port which is installed to download the data of the payload meter.
1. Automatic transmission
When dumping is finished, the data of the concerned cycle are transmitted automatically.
The data saved in the payload meter can be made by accumulating the above cycle data with the sys-
tem on the user side.
2. MMS communication
If the mass of a bucketful is recognized, the load mass at that time is transmitted automatically.
If the final load mass (hauled load mass of the concerned cycle) is entered, its value is transmitted auto-
matically.
Upon receiving a request command, the load mass is transmitted in real time.
RS232C is used for only the selected one of data downloading, automatic transmission, and MMS communi-
cation.
q Specifications of RS232C connection
Baud rate: 9600 bps
Data length: 8 bits
Stop bit: 2 bits
Parity: Not applied
Flow control: Not executed
q Connection of RS232C (communication line) (3-wire method)
q Selecting wiring harness for downloading/automatic transmission/MMS communication
18 HD465-7R, HD605-7R
q Distinction of communication control codes

The transmitting side transmits data as explained below so that the data in a communication from begin-
ning with STX and finishing with EXT and BCC will have permeability.
1) If there is a code which is the same as STX or ETX in the data area of the communication frame,
DLE (10h) is inserted just before that code.
2) If there is a code which is the same as DLE in the data area of the communication frame, DLE (10h)
is inserted just before that code.
3) Calculation of BCC
XOR (Exclusive-or) is checked in order from STX at the head of the frame to ETX just before BCC,
including inserted DLE.
When one of 02h (STX), 03h (ETX), and 10h (DLE) is included in the data
Original frame
STX (02h) ••• STX (02h) ••• ETX (03h) BCC
Transmitted frame
STX (02h) ••• DLE (10h) STX (02h) ••• ETX (03h) BCC
HD465-7R, HD605-7R 19
q Automatic transmission
(a) Timing of transmission
The operation data of the concerned cycle are transmitted automatically when the concerned cycle
data are entered (when dumping is finished).
(b) Contents of communication
Format (VHMS controller External device)
STX (02h) [1] ETX (03h) BCC
[1]: Cycle data {39 bytes including header (ASCII L)}

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

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

If "NAK" is returned, the VHMS controller transmits up to 2 more times. If "NAK" is still returned, the
VHMS controller stops transmission.
20 HD465-7R, HD605-7R
q MMS communication
Transmission of unit distinction setting
After the VHMS controller is started by turning the key to the ON position, it transmits the unit dis-
tinction setting information automatically.
Format (VHMS controller )
STX (02h) [1] [2] ETX (03h) BCC
[1]: K (ASCII) fixed

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

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

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

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

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

or

sion.
Transmission of final load mass

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

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

or
22 HD465-7R, HD605-7R

sion.
Transmission of real-time data

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

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

Transmission of the real-time data from the VHMS controller is used as a substitute for the
answer.
HD465-7R, HD605-7R 23
2) Transmission of real-time data (VHMS controller )

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

[4]: Real-time data (17 BYTES)
From head
Signal name Position Name HEX
(Lower position)
P FL (Upper position) Front left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P FR (Upper position) Front right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RL (Upper position) Rear left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RR (Upper position) Rear right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
INC (Upper position) Inclination angle (degree) [Complement of 2 of 100-time value]
(Lower position)
PAYLD (Upper position) Real-time load mass (Metric ton) [10-time value, to 1 decimal place]
SP (Current) Travel speed (km/h) 0 – 99
DIG STST Status of digital signals See (*1)
ANA 1 Unused 0
ANA 2 Unused 0
VEH STAT Status of dump truck See (*2)
(*1) Status of digital signals [HEX]

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

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

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

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

Answer (VHMS controller )

STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
HD465-7R, HD605-7R 25
Sensors, switches 1
Engine speed sensor
1. Magnet Function
2. Locknut q The engine speed sensor is installed to the
3. Wiring harness ring gear of the flywheel housing. It uses the
4. Connector rotation of the gear teeth to generate a pulse
voltage and transmits a signal to the transmis-
sion controller.
26 HD465-7R, HD605-7R
Accelerator sensor
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
q This is installed under the operator’s cab. The q This is installed under the operator’s cab.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator 2 (No. 5 pin) is connected to the ground; when
pedal is depressed, the movement is passed the accelerator pedal is depressed, signal 3
through the link and rotates the shaft of the (No. 6 pin) is connected to the ground.
potentiometer inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3
pins of the potentiometer. A voltage signal cor-
responding to the angle of the accelerator
pedal is sent from the No. 2 pin to the engine
controller.
HD465-7R, HD605-7R 27
Retarder oil temperature sensor

Steering oil temperature sensor
1. Thermistor Function
2. Plug q The retarder oil temperature sensor is installed
3. Wiring harness on the retarder pipe. It converts a temperature
4. Connector change into a change of thermistor resistance,
and transmits a signal to the transmission con-
troller. The transmission controller transmits
the signal via the network to the machine mon-
itor panel, and the machine monitor panel dis-
plays a temperature level. The temperature
level displayed on the monitor panel reaches a
predetermined position, the lamp flashes and
the warning buzzer sounds.
q The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor
portion detects the temperature, and when the
oil temperature goes above the specified level,
the warning lamps lights up and a message is
displayed on the character display of the mon-
itor panel.
28 HD465-7R, HD605-7R
Coolant level sensor
1. Float Function
2. Sensor q This sensor is installed to the top of the radia-
3. Connector tor, and when the coolant level goes below the
specified level, the float goes down and the
switch goes OFF. The maintenance caution
lamp lights up and the character display shows
message to warn of abnormality.
HD465-7R, HD605-7R 29
Fuel level secsor
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according to the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level. When the display of the monitor panel
reaches a certain level, a warning lamp
flashes.
30 HD465-7R, HD605-7R
Transmission oil filter clogging sensor
1. Body Function
2. Tube q This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A : Low pressure pickup port side and high-pressure side reaches the speci-
B : High pressure pickup port fied pressure, the switch goes OFF. The main-
tenance caution lamp lights up and the
character display shown message to warn of
abnormality.
Actuating pressure: 275 kPa {2.8 kg/cm2}
Principle of switch: Pressure difference sliding pis-

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

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

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

of the suspension cylinder and acts to measure the
pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the

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

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

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

(For VHMS)
Specifications
1. Voltage of power supply: DC5V Specifications
2. Output voltage : 0.5V(engine stopped) 1. Type of sensor : Thermistor
or more 2. Range of measurement : 40 – 130 °C
3. Size: Mount (portion a) : R 1/4 : 80 – 130 °C
: Outside diameter of (guaranteed precision
seat receiving pres- ± 2 °C)
sure: 37 mm 3. Max. power consumption: 0.5 mW
: Length of cable: 4. Pressure resistance : 4.9 MPa {50 kg/cm2}
1,110 mm 5. Temperature range : --30 to 140 °C
6. Performance table
Function
The blow-by sensor converts the pressure inside Tempera- Resis- Tempera- Resis- Tempera- Resis-
ture tance ture tance ture tance
the engine crankcase into a voltage and inputs this (°C) (kz) (°C) (kz) (°C) (kz)
into the VHMS controller as the blow-by pressure.
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
Function
The engine oil temperature sensor is installed to
the engine oil filter. It inputs the change in tempera-
ture to the VHMS controller as a change in the
resistance of the thermistor.
a: Heat sensing portion of sensor, outside diame-

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

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

(ambient temperature: 20 °C) ••• Reference value Function
The ambient temperature sensor inputs the ambi-
Detection ent temperature to the VHMS controller as a
temperature 50 100 400 700 800
(°C) change in the resistance of the thermistor.
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
a: Heat sensing portion of sensor, diameter of

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

© 2006 KOMATSU
All Rights Reserved
42 HD465-7R, HD605-7R
SEN02313-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
90 Diagrams and drawings 1

Hydraulic circuit diagram
Power train hydraulic circuit diagram .............................................................................................................. 2
Steering and hoist hydraulic circuit diagram ................................................................................................... 3
Brake hydraulic circuit diagram....................................................................................................................... 5
HD465-7R, HD605-7R 1
SEN02313-00 90 Diagrams and drawings
Power train hydraulic circuit diagram 1
2 HD465-7R, HD605-7R
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD465-7R, HD605-7R
HD465-7R, HD605-7R 3
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HD465-7R, HD605-7R
HD465-7R, HD605-7R 5

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R
SEN02314-00
DUMP TRUCK
HD465-7R
HD605-7R

HD465-7R 15001 and up
HD605-7R 16001 and up
90 Diagrams and drawings 1

Electrical circuit diagram
Electrical circuit diagram inside cab (1/2) ....................................................................................................... 3
Electrical circuit diagram outside cab (2/2) ..................................................................................................... 5
HD465-7R, HD605-7R 1
Electrical circuit diagram for inside cab (1/2) HD465-7R, HD605-7R Electrical circuit diagram for inside cab (1/2)
HD465-7R, HD605-7R
SEN02314-00
HD465-7R, HD605-7R 3
Electrical circuit diagram for outside cab (2/2) HD465-7R, HD605-7R Electrical circuit diagram for outside cab (2/2)
HD465-7R, HD605-7R
SEN02314-00
HD465-7R, HD605-7R 5

© 2006 KOMATSU
All Rights Reserved
8 HD465-7R, HD605-7R

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What are the main components of the dump truck discussed in the manual?

What are the main components of the dump truck discussed in the manual?

What systems are described in the manual and what do they cover?

What systems are described in the manual and what do they cover?

SEN02283-00

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

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

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02283-00

00 Index and foreword SEN02284-00

10 Structure, function and maintenance standard SEN02290-00

90 Diagrams and drawings SEN02312-00

Foreword and general information SEN02286-00

10 Structure, function and maintenance standard

Accumulator charge valve ........................................................................................................... 10

90 Diagrams and drawings

HD465-7R, HD605-7R Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness